*OMT223334*
27D
Excavator
OPERATOR'S MANUAL
27D Excavator
OMT223334 ISSUE H3
(ENGLISH)
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
If this product contains a gasoline engine:
WARNING
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm.
The State of California requires the above two warnings.
Additional Proposition 65 Warnings can be found in this manual.
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
Introduction
Emission Control Statement
EMISSIONS CONTROL WARRANTY STATEMENT FOR
NEW JOHN DEERE CONSTRUCTION EQUIPMENT (U.S. AND CANADA)
To determine if the engine in your machine qualifies for the additional warranties set forth below, look for the "Engine Information"
label located on your engine. If you reside in the United States and the engine label states: "Engine conforms to
US EPA regulations on heavy duty non road diesel cycle engines," you are entitled to the "U.S. Emission Control Warranty
Statement." If you reside in California, and the engine label states: "Engine conforms to California regulations on heavy duty
non road diesel cycle engines," you are entitled to the "California Emission Control Warranty Statement."
U.S. EPA EMISSIONS CONTROL WARRANTY STATEMENT
Warranties stated on this certificate refer only to emissions-related
parts and components of your engine. The complete machine
warranty, less emisions-related parts and components, is
provided separately as "John Deere "Secure Warranty" For New
Construction Products."
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and John Deere are
pleased to explain the emission control system on your new
engine. In California, new heavy-duty engines must be designed,
built and equipped to meet the State's stringent anti-smog
standards. John Deere must warrant the emission control system
on your engine for the periods of time listed below provided there
has been no abuse, neglect, or improper maintenance of your
machine.
Your emissions control system includes:
Fuel Metering System
Fuel Injection System
Air Induction System
Intake Manifold
Turbocharger System
Charge Air Cooling System
Miscellaneous Items used in Above Systems
Where a warrantable condition exists, i.e. failure due to defect in
John Deere-supplied material and/or workmanship, John Deere
will repair your heavy-duty engine at no cost to you including
diagnosis, parts and labor
JOHN DEERE'S WARRANTY COVERAGE:
The emission control system of your heavy-duty engine is
warranted for five years or 3000 hours of operation, whichever
occurs first. If any emission-related part on your engine is
defective, the part will be repaired or replaced by John Deere.
Warranties stated on this certificate refer only to emissions-related
parts and components of your engine. The complete machine
warranty, less emissions-related parts and components, is
provided separately as the "John Deere "Secure Warranty" For
New Construction Products."
OWNER'S WARRANTY RESPONSIBILITIES:
As the heavy-duty engine owner, you are responsible for the
performance of the required maintenance as outlined in the
Operator's Manual. John Deere recommends that you retain all
receipts covering maintenance on your heavy-duty engine, but
John Deere cannot deny warranty solely for the lack of receipts
or for your failure to ensure the performance of all scheduled
maintenance.
However, as the heavy-duty engine owner, you should be aware
that John Deere may deny you warranty coverage if your heavyduty engine or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.
Your engine is designed to operate on diesel fuel only. Use of
any other fuel may result in your engine no longer operating in
compliance with California's emissions requirements.
You are responsible for initiating the warranty process. The CARB
suggests that you present your machine to the nearest authorized
John Deere dealer as soon as a problem is suspected. The
warranty repairs should be completed by the service dealer as
expeditiously as possible.
If you have any questions regarding your warranty rights and
responsibilities, you should contact John Deere at 1-319-2925400, or the State of California Air Resources Board, Mobile Source
Operation Division, PO Box 8001, El Monte, CA 91731-2900
The warranty period begins on the date the machine is delivered
to an ultimate purchaser, or when otherwise put into service.
John Deere warrants to the ultimate purchaser and each
subsequent purchaser that the engine is designed, built and
equipped so as to conform with all applicable regulations adopted
by the Air Resources Board, and that it is free from defects in
materials and workmanship which would cause the failure of a
warranted part.
Any warranted part which is scheduled for replacement as
required maintenance by the operator's manual is warranted by
John Deere for the period of time prior to the first scheduled
replacement point for that part. If the part fails prior to the first
scheduled replacement point, the part shall be repaired or
replaced under warranty. Any such part repaired or replaced
under warranty is warranted for the remainder of the period prior
to the first scheduled replacement point for that part.
Any warranted part which is not scheduled for replacement as
required maintenance, or which is scheduled only for regular
inspection to the effect of repairing or replacing as necessary, is
warranted for the warranty period.
Repair or replacement of a warranted part will be performed at no
charge to you by an authorized John Deere dealer. You will not
be charged for diagnostic labor which leads to the determination
that a warranted part is defective, if the diagnostic work is
performed by a John Deere dealer.
John Deere is liable for damages to other engine components
caused by failure under warranty of any warranted part.
John Deere is NOT liable for travel or mileage on extended
emissions warranty service calls.
Any replacement part may be used in the performance of any
maintenance or repairs, and such use will not reduce the warranty
obligations of John Deere. However, the use of add-on or
modified parts are grounds for disallowing a warranty claim.
T132126 —19—28JUN00
Emissions control-related parts and components are warranted
by John Deere for five years or 3000 hours of operation, whichever
occurs first. John Deere further warrants that the engine covered
by this warranty was designed, built, and equipped so as to
conform at the time of sale with all U.S. emissions standards at
the time of manufacture, and that it is free of defects in materials
and workmanship which would cause it not to meet these
standards within the period of five years or 3000 hours of
operations, whichever occurs first.
OUO1065,000006C -19-08JAN08-1/1
080913
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Introduction
Technical Information Feedback Form
We need your help to continually improve our technical
publications. Please copy this page and FAX or mail your
comments, ideas and improvements.
SEND TO:
John Deere Dubuque Works
18600 South John Deere Road
Attn: Publications, Dept. 324
Dubuque, IA 52004-0538
USA
FAX NUMBER: 1-563-589-5800 (USA)
Publication Number:
Page Number:
Ideas, Comments:
Name:
Phone:
Email Address:
THANK YOU!
TX,TM,FAX -19-03JUL01-1/1
080913
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Introduction
080913
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Contents
Page
Page
Safety—Safety and Operator Convenience
Monitor Panel and Functions (S.N.
255551— ) ....................................................2-1-2
Switch Panel—Cab............................................2-1-3
Switch Panel—Canopy......................................2-1-4
Pedals and Levers.............................................2-1-4
Engine Speed Control Lever .............................2-1-4
Pilot Control Shutoff Lever.................................2-1-5
Setting Trip Meters ............................................2-1-6
Door Release Lever—If Equipped.....................2-1-7
Front (Secondary Exit) Window—If Equipped ...2-1-8
Secondary Exit Tool—If Equipped .....................2-1-9
Opening Rear Window—If Equipped.................2-1-9
Opening Right Side Window—If Equipped........2-1-9
Adjusting Operator Seat ..................................2-1-10
Toolbox and Operator’s Manual
Compartment ..............................................2-1-10
Safety and Operator Convenience Features .....1-1-1
Safety—General Precautions
Recognize Safety Information ...........................1-2-1
Follow Safety Instructions..................................1-2-1
Operate Only If Qualified ...................................1-2-1
Wear Protective Equipment...............................1-2-2
Avoid Unauthorized Machine Modifications.......1-2-2
Add Cab Guarding for Special Uses..................1-2-2
Inspect Machine ................................................1-2-2
Stay Clear of Moving Parts................................1-2-3
Avoid High-Pressure Fluids ...............................1-2-3
Avoid High-Pressure Oils ..................................1-2-3
Work In Ventilated Area.....................................1-2-4
Prevent Fires .....................................................1-2-4
Prevent Battery Explosions ...............................1-2-5
Handle Chemical Products Safely .....................1-2-5
Dispose of Waste Properly ................................1-2-5
Prepare for Emergencies...................................1-2-6
Operation—Operating the Machine
Before Starting Work .........................................2-2-1
Operator's Daily Machine Check
Before Starting ..............................................2-2-1
Starting the Engine ............................................2-2-2
Starting the Engine in Cold Weather .................2-2-3
Checking Instruments After Starting..................2-2-4
Cold Weather Warm-Up ....................................2-2-4
Travel Pedals and Levers..................................2-2-5
Control Lever Pattern Operation........................2-2-6
Control Lever Pattern Conversion .....................2-2-7
Multi-Function Control Lever—If Equipped........2-2-7
Boom-Swing Pedal ............................................2-2-8
Auxiliary Pedal...................................................2-2-8
Positioning Auxiliary Line Selector Valve...........2-2-9
Operating Backfill Blade ..................................2-2-10
Operating Tips—Backfill Blade........................2-2-10
Operating in Water and Mud ...........................2-2-11
Selecting Correct Track ...................................2-2-11
Driving Up a Steep or Slippery Slope ..............2-2-11
Lowering Boom With Engine Stopped.............2-2-12
Parking ............................................................2-2-13
Loading and Unloading for Transport ..............2-2-13
Towing Machine a Short Distance ...................2-2-14
Lifting ...............................................................2-2-14
Lifting Machine ................................................2-2-15
Safety—Operating Precautions
Use Steps and Handholds Correctly .................1-3-1
Start Only From Operator's Seat .......................1-3-1
Use and Maintain Seat Belt ...............................1-3-1
Prevent Unintended Machine Movement ..........1-3-1
Avoid Work Site Hazards...................................1-3-2
Keep Riders Off Machine ..................................1-3-2
Avoid Backover Accidents .................................1-3-3
Avoid Machine Tip Over ....................................1-3-3
Use Special Care When Lifting Objects ............1-3-4
Add and Operate Attachments Safely ...............1-3-4
Safety—Maintenance Precautions
Park and Prepare for Service Safely .................1-4-1
Service Cooling System Safely .........................1-4-1
Remove Paint Before Welding or Heating.........1-4-2
Make Welding Repairs Safely ...........................1-4-2
Drive Metal Pins Safely .....................................1-4-2
Safety—Safety Signs
Safety Signs ......................................................1-5-1
Operation—Operator Station
Maintenance—Machine
Monitor Panel and Functions (S.N. —255551) ..2-1-1
Diesel Fuel.........................................................3-1-1
Continued on next page
Original Instructions. All information, illustrations and specifications in this
manual are based on the latest information available at the time of publication.
The right is reserved to make changes at any time without notice.
COPYRIGHT © 2013
DEERE & COMPANY
Moline, Illinois
All rights reserved.
A John Deere ILLUSTRUCTION ® Manual
Previous Editions
Copyright © 2005, 2006, 2007, 2008, 2009
i
080913
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Contents
Page
Page
Lubricity of Diesel Fuel ......................................3-1-1
Handling and Storing Diesel Fuel ......................3-1-2
Biodiesel Fuel ....................................................3-1-3
Testing Diesel Fuel ............................................3-1-4
Minimizing the Effect of Cold Weather
on Diesel Engines .........................................3-1-5
Alternative and Synthetic Lubricants .................3-1-6
Diesel Engine Oil ...............................................3-1-6
Diesel Engine Oil and Filter Service Intervals ...3-1-7
Hydraulic Oil ......................................................3-1-8
Travel Gearbox Oil ............................................3-1-8
Grease...............................................................3-1-9
Light Duty Diesel Engine Coolant (for
diesel engines without wet sleeve
cylinder liners) .............................................3-1-10
Drain Intervals for Diesel Engine Coolant........3-1-10
John Deere COOL-GARD™ II Coolant
Extender......................................................3-1-11
Supplemental Coolant Additives......................3-1-11
Operating in Warm Temperature Climates ......3-1-12
Additional Information About Diesel
Engine Coolants and John Deere
COOL-GARD™ II Coolant Extender ...........3-1-13
Testing Diesel Engine Coolant.........................3-1-14
Seat Belt ............................................................3-4-7
Maintenance—First 50, Then Every 100 Hours
Lubricate Bucket and Link Pins .........................3-5-1
Grease Front Joint Pins.....................................3-5-2
Inspect Fan Belt, Check and Adjust Tension .....3-5-3
Maintenance—Every 250 Hours
Grease Swing Bearing.......................................3-6-1
Checking Travel Gearbox Oil Level...................3-6-1
Draining Hydraulic Oil Tank Sump.....................3-6-2
Replacing Hydraulic Oil Tank Filter....................3-6-2
Take Engine Oil Sample ....................................3-6-3
Maintenance—Every 500 Hours
Changing Engine Oil and Replacing Filter.........3-7-1
Lubricate Swing Bearing Gear...........................3-7-1
Lubricate Control Lever Universal Joint.............3-7-1
Replacing Final Fuel Filter.................................3-7-2
Lubricate Blade Pins..........................................3-7-2
Replacing Air Cleaner Element .........................3-7-3
Replacing Hydraulic Oil Tank Filter....................3-7-3
Take Fluid Samples ...........................................3-7-3
Maintenance—Every 1000 Hours
Maintenance—Periodic Maintenance
Changing Travel Gearbox Oil ............................3-8-1
Replacing Pilot System Oil Filter .......................3-8-2
Checking and Adjusting Engine Valve
Lash (Clearance)...........................................3-8-3
Checking Starter and Alternator ........................3-8-3
Check Coolant ...................................................3-8-3
Service Machine at Specified Intervals..............3-2-1
Check the Hour Meter Regularly .......................3-2-1
Preparing Machine for Maintenance..................3-2-1
Engine Access Door ..........................................3-2-2
Maintenance Access Cover...............................3-2-2
Tilting the Operator Station................................3-2-3
Fuel Tank ...........................................................3-2-4
Checking Washer Fluid Level............................3-2-4
Hydraulic Breaker and Crusher Attachments ....3-2-5
Fluid Analysis Program Test Kits and
3-Way Coolant Test Kit..................................3-2-5
Service Intervals ................................................3-2-6
Required Parts...................................................3-2-8
Maintenance—Every 2000 Hours
Draining Cooling System ...................................3-9-1
Cooling System Fill and Deaeration ..................3-9-2
Changing Hydraulic Tank Oil and
Cleaning Suction Screen...............................3-9-2
Maintenance—Every 6000 Hours
Maintenance—As Required
Draining Cooling System .................................3-10-1
Cooling System Fill and Deaeration ................3-10-2
Cleaning Air Cleaner Element ...........................3-3-1
Cleaning Radiator Core and Oil Cooler .............3-3-1
Check Coolant ...................................................3-3-2
Miscellaneous—Machine
Do Not Service or Adjust Injection
Nozzles or High Pressure Fuel Pump ...........4-1-1
Do Not Service Control Valves,
Cylinders, Pumps, or Motors.........................4-1-1
Precautions for Alternator and Regulator ..........4-1-1
Handling, Checking, and Servicing
Batteries Carefully.........................................4-1-2
Using Booster Batteries—12-Volt System .........4-1-3
Using Battery Charger .......................................4-1-4
Replacing the Battery ........................................4-1-4
Welding On Machine .........................................4-1-4
Bleed Hydraulic System ....................................4-1-5
Maintenance—Every 10 Hours or Daily
Checking Engine Oil Level ................................3-4-1
Checking Hydraulic Oil Tank Level ....................3-4-1
Draining Fuel Tank Sump ..................................3-4-2
Draining Water Separator..................................3-4-3
Checking Recovery Tank Coolant Level............3-4-4
Checking Bucket Teeth......................................3-4-4
Checking Track Sag—Rubber Track .................3-4-4
Checking Track Sag—Steel Track—If
Equipped .......................................................3-4-6
Track Sag General Information .........................3-4-6
Adjusting Track Sag ..........................................3-4-7
Continued on next page
ii
080913
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Contents
Page
Clean Machine Regularly ..................................4-1-5
12-Volt Auxiliary Power Outlet ...........................4-1-5
Connecting and Disconnecting
Auxiliary Lines ...............................................4-1-6
Replacing Fuses................................................4-1-7
Cleaning Heating and Air Conditioning
Filter Screens—If Equipped ..........................4-1-8
Installing Bucket With Quick Coupler ................4-1-9
Checking Track Shoe Hardware......................4-1-10
Rubber Track Care ..........................................4-1-10
Removing and Installing Rubber Track ...........4-1-11
Converting the Track .......................................4-1-12
Unified Inch Bolt and Screw Torque Values.....4-1-12
Metric Bolt and Screw Torque Values..............4-1-13
Miscellaneous—Operational Checkout
Operational Checkout........................................4-2-1
Miscellaneous—Troubleshooting
Using Troubleshooting Charts ...........................4-3-1
Engine ...............................................................4-3-2
Electrical System ...............................................4-3-5
Hydraulic System...............................................4-3-7
Miscellaneous—Storage
Prepare Machine for Storage ............................4-4-1
Monthly Storage Procedure...............................4-4-1
Miscellaneous—Serial Numbers
Record Product Identification Number (PIN) .....4-5-1
Record Engine Serial Number...........................4-5-1
Keep Proof of Ownership ..................................4-5-1
Keep Machines Secure .....................................4-5-2
Miscellaneous—Specifications
Engine Specifications ........................................4-6-1
Drain and Refill Capacities ................................4-6-1
Machine Specifications......................................4-6-2
Working Ranges ................................................4-6-4
Excavator Lift Capacity (Blade on the
Ground With Standard Boom and Canopy) ..4-6-6
Excavator Lift Capacity (Blade on the
Ground With Long Arm and Canopy)............4-6-7
Excavator Lift Capacity (Blade on the
Ground With Standard Boom and Cab) ........4-6-8
Excavator Lift Capacity (Blade on the
Ground With Long Arm and Cab)..................4-6-9
iii
080913
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Contents
iv
080913
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Safety—Safety and Operator Convenience
Safety and Operator Convenience Features
1
4
8
2
3
7
6
T217409 —UN—07DEC05
9
5
T217409
Canopy Model Shown
Please remember that the operator is the key to
preventing accidents.
6. Travel Alarm. Alerts bystanders of machine movement
when traveling.
1. ROPS/TOPS/FOPS. A protective structure protects the
operator of the compact excavator.
7. Fan Guard. A fan guard inside the engine compartment
helps prevent contact with the fan blades.
2. Seat belt. A seat belt is provided for the operator.
8. Horn. Standard horn is useful when driving or signaling
co-workers.
3. Pilot Control Shutoff. A lever near the cab exit
reminds the operator to deactivate hydraulic functions
before leaving the machine and prevents engine startup
unless lever is in locked position.
4. Handholds. Large, conveniently placed handholds
make it easy to enter or exit the operator's station or
service area.
9. Cab with Heater/Defroster/Air Conditioner.
Circulates both outside and inside air through filters for a
clean working environment. Built-in defroster vents direct
air flow for effective window defogging/deicing.
5. Swing Brake. Swing brake is engaged when the pilot
control shutoff lever is raised. Helps secure upperstructure
when transporting the machine.
MM61211,0000A56 -19-14DEC05-1/1
1-1-1
080913
PN=9
Safety—General Precautions
Recognize Safety Information
T133555 —UN—15APR13
This is the safety alert symbol. When this symbol is
noticed on the machine or in this manual, be alert for
the potential of personal injury.
Follow the precautions and safe operating practices
highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION —
is used with the safety alert symbol. DANGER identifies
the most serious hazards.
T133588 —19—28AUG00
On the machine, DANGER signs are red in color,
WARNING signs are orange, and CAUTION signs are
yellow. DANGER and WARNING signs are located near
specific hazards. General precautions are on CAUTION
labels.
TX03679,00016CC -19-03JAN07-1/1
Follow Safety Instructions
T133556 —UN—24AUG00
Read the safety messages in this manual and on the
machine. Follow these warnings and instructions carefully.
Review them frequently.
Be sure all operators of this machine understand every
safety message. Replace operator's manual and safety
labels immediately if missing or damaged.
TX03679,00016F9 -19-03JAN07-1/1
Operate Only If Qualified
Do not operate this machine unless the operator's manual
has been read carefully, and you have been qualified by
supervised training and instruction.
Operator should be familiar with the job site and
surroundings before operating. Try all controls and
machine functions with the machine in an open area
before starting to work.
Know and observe all safety rules that may apply to every
work situation and work site.
TX03679,00016FA -19-03JAN07-1/1
1-2-1
080913
PN=10
Safety—General Precautions
Wear Protective Equipment
Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
TS206 —UN—15APR13
Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause impairment
or loss of hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against objectionable
or uncomfortable loud noises.
TX03679,00016D0 -19-03JAN07-1/1
Avoid Unauthorized Machine Modifications
John Deere recommends using only genuine John Deere
replacement parts to ensure machine performance.
Never substitute genuine John Deere parts with alternate
parts not intended for the application as these can
create hazardous situations or hazardous performance.
Non-John Deere parts, or any damage or failures resulting
from their use are not covered by any John Deere warranty.
Modifications of this machine, or addition of unapproved
products or attachments, may affect machine stability or
reliability, and may create a hazard for the operator or
others near the machine. The installer of any modification
which may affect the electronic controls of this machine is
responsible for establishing that the modification does not
adversely affect the machine or its performance.
Always contact an authorized dealer before making
machine modifications that change the intended use,
weight or balance of the machine, or that alter machine
controls, performance or reliability.
AM40430,00000A9 -19-20AUG09-1/1
Add Cab Guarding for Special Uses
Special work situations or machine attachments may
create an environment where special additional guarding
is needed to protect the operator.
Special screens or guarding should be installed to prevent
machine damage. Contact your authorized dealer for
information on devices intended to provide protection in
special work situations.
MM61211,0000A54 -19-25JAN07-1/1
Inspect Machine
Keep all guards and shields in good condition and properly
installed. Fix damage and replace worn or broken parts
immediately. Pay special attention to hydraulic hoses and
electrical wiring.
T6607AQ —UN—15APR13
Inspect machine carefully each day by walking around it
before starting.
TX03679,0001734 -19-03JAN07-1/1
1-2-2
080913
PN=11
Safety—General Precautions
T133592 —UN—15APR13
Stay Clear of Moving Parts
Entanglements in moving parts can cause serious injury.
Stop engine before examining, adjusting or maintaining
any part of machine with moving parts.
Keep guards and shields in place. Replace any guard
or shield that has been removed for access as soon as
service or repair is complete.
TX03679,00016D2 -19-03JAN07-1/1
Avoid High-Pressure Fluids
X9811 —UN—23AUG88
Inspect hydraulic hoses periodically – at least once
per year – for leakage, kinking, cuts, cracks, abrasion,
blisters, corrosion, exposed wire braid or any other signs
of wear or damage.
Replace worn or damaged hose assemblies immediately
with John Deere approved replacement parts.
Escaping fluid under pressure can penetrate the skin
causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid
injected into the skin must be surgically removed within
a few hours or gangrene may result. Doctors unfamiliar
with this type of injury should reference a knowledgeable
medical source. Such information is available in
English from Deere & Company Medical Department in
Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1
309-748-5636.
DX,FLUID -19-12OCT11-1/1
Avoid High-Pressure Oils
Never search for leaks with your hands. Protect hands.
Use a piece of cardboard to find location of escaping oil.
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.
T133840 —UN—20SEP00
If hydraulic oil penetrates your skin, see a doctor
immediately. Injected oil must be removed surgically
within hours or gangrene may result. Contact a
knowledgeable medical source or the Deere & Company
Medical Department in Moline, Illinois, U.S.A.
T133509 —UN—15APR13
This machine uses a high-pressure hydraulic system.
Escaping oil under pressure can penetrate the skin
causing serious injury.
TX03679,00016D3 -19-03NOV08-1/1
1-2-3
080913
PN=12
Safety—General Precautions
Work In Ventilated Area
Engine exhaust fumes can cause sickness or death. If
it is necessary to run an engine in an enclosed area,
remove the exhaust fumes from the area with an exhaust
pipe extension.
TS220 —UN—15APR13
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.
DX,AIR -19-17FEB99-1/1
T133552 —UN—15APR13
Prevent Fires
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines, exhaust components, and
electrical wiring. Never store oily rags or flammable
materials inside a machine compartment.
T133553 —UN—07SEP00
Maintain Hoses and Wiring: Replace hydraulic hoses
immediately if they begin to leak, and clean up any oil
spills. Examine electrical wiring and connectors frequently
for damage.
Keep A Fire Extinguisher Available: Always keep a
multipurpose fire extinguisher on or near the machine.
Know how to use extinguisher properly.
T133554 —UN—07SEP00
TX03679,00016F5 -19-03NOV08-1/1
1-2-4
080913
PN=13
Safety—General Precautions
Prevent Battery Explosions
Battery gas can explode. Keep sparks, lighted matches,
and open flame away from the top of battery.
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
TS204 —UN—15APR13
Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
TX03679,000174A -19-03NOV08-1/1
Exposure to hazardous chemicals can cause serious
injury. Under certain conditions, lubricants, coolants,
paints and adhesives used with this machine may be
hazardous.
If uncertain about safe handling or use of these chemical
products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS) or go to internet website
http://www.jdmsds.com. The MSDS describes physical
and health hazards, safe use procedures, and emergency
response techniques for chemical substances. Follow
MSDS recommendations to handle chemical products
safely.
T133580 —UN—25AUG00
Handle Chemical Products Safely
TX03679,00016D7 -19-03JAN07-1/1
Improper disposal of waste can threaten the environment.
Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants can damage the atmosphere.
Government regulations may require using a certified
service center to recover and recycle used refrigerants.
T133567 —UN—25AUG00
Dispose of Waste Properly
If uncertain about the safe disposal of waste, contact your
local environmental or recycling center or your authorized
dealer for more information.
TX03679,0001733 -19-03JAN07-1/1
1-2-5
080913
PN=14
Safety—General Precautions
Prepare for Emergencies
Be prepared if an emergency occurs or a fire starts.
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
TS291 —UN—15APR13
Keep a first aid kit and fire extinguisher handy.
TX03679,000174B -19-03JAN07-1/1
1-2-6
080913
PN=15
Safety—Operating Precautions
Prevent falls by facing the machine when getting on and
off. Maintain 3-point contact with steps and handrails.
Never use machine controls as handholds.
Use extra care when mud, snow, or moisture present
slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.
T133468 —UN—15APR13
Use Steps and Handholds Correctly
TX03679,00016F2 -19-24APR13-1/1
Avoid unexpected machine movement. Start engine only
while sitting in operator's seat. Ensure all controls and
working tools are in proper position for a parked machine.
Never attempt to start engine from the ground. Do not
attempt to start engine by shorting across the starter
solenoid terminals.
T133715 —UN—15APR13
Start Only From Operator's Seat
TX03679,0001799 -19-22APR10-1/1
Use seat belt when operating machine. Remember to
fasten seat belt when loading and unloading from trucks
and during other uses.
Examine seat belt frequently. Be sure webbing is not
cut or torn. Replace seat belt immediately if any part is
damaged or does not function properly.
T133716 —19—17APR13
Use and Maintain Seat Belt
The complete seat belt assembly should be replaced
every 3 years, regardless of appearance.
TX03679,00016DD -19-03NOV08-1/1
Be careful not to accidentally actuate control levers when
coworkers are present. Pull pilot shutoff lever to locked
(UP) position during work interruptions. Pull pilot shutoff
lever to locked (UP) position and stop engine before
allowing anyone to approach machine.
Always lower work equipment to the ground and pull pilot
shutoff lever to locked (UP) position before standing up or
leaving the operator's seat. Stop engine before exiting.
T216779 —UN—22NOV05
Prevent Unintended Machine Movement
VD76477,000036D -19-19APR11-1/1
1-3-1
080913
PN=16
Safety—Operating Precautions
Avoid boom or arm contact with overhead obstacles
or overhead electrical lines. Never move any part of
machine or load closer than 3 m (10 ft) plus twice the line
insulator length to overhead wires.
Keep bystanders clear at all times. Keep bystanders
away from raised booms, attachments, and unsupported
loads. Avoid swinging or raising booms, attachments, or
loads over or near personnel. Use barricades or a signal
person to keep vehicles and pedestrians away. Use a
signal person if moving machine in congested areas or
where visibility is restricted. Always keep signal person in
view. Coordinate hand signals before starting machine.
Operate only on solid footing with strength sufficient to
support machine. When working close to an excavation,
position travel motors away from the hole.
Reduce machine speed when operating with tool on or
near ground when obstacles may be hidden (e.g., during
snow removal or clearing mud, dirt, etc). At high speeds
hitting obstacles (rocks, uneven concrete or manholes)
can cause a sudden stop. Always wear your seat belt.
T133650 —UN—27SEP00
Prepare work site properly. Avoid operating near
structures or objects that could fall onto the machine. Clear
away debris that could move unexpectedly if run over.
T133549 —UN—24AUG00
Avoid contact with gas lines, buried cables and water
lines. Call utility line location services to identify all
underground utilities before you dig.
T134986 —UN—31OCT00
Avoid Work Site Hazards
MM61211,0000A57 -19-07JAN09-1/1
Keep Riders Off Machine
Riders are subject to injury. They may fall from machine,
be caught between machine parts, or be struck by foreign
objects.
Riders may obstruct operator’s view or impair his ability
to operate machine safely.
T120807 —UN—14APR99
Only allow operator on machine.
TX14740,0001E7A -19-19MAR02-1/1
1-3-2
080913
PN=17
Safety—Operating Precautions
Avoid Backover Accidents
Be certain travel alarm is working properly.
Use a signal person when backing if view is obstructed
or when in close quarters. Keep signal person in view at
all times. Use prearranged hand signals to communicate.
T120806 —UN—14APR99
Before moving machine, be sure all persons are clear
of both travel and swing paths. Turn around and look
directly for best visibility. Keep windows clean, adjusted,
and in good repair.
OUO1032,00015D0 -19-25JAN07-1/1
Load and unload from trucks or trailers carefully. Be
sure truck is wide enough and on a firm level surface.
Use loading ramps and attach them properly to truck bed.
Avoid trucks with steel beds because tracks slip more
easily on steel.
Be careful on slopes. Use extra care on soft, rocky
or frozen ground. Machine may slip sideways in these
conditions. When traveling up or down slopes, keep the
bucket on uphill side and just above ground level.
Be careful with heavy loads. Using oversize buckets or
lifting heavy objects reduces machine stability. Extending
a heavy load or swinging it over side of undercarriage
may cause machine to tip.
Ensure solid footing. Use extra care when operating
near banks or excavations that may cave-in and cause
machine to tip or fall.
T133545 —UN—15SEP00
Do not jump if the machine tips. You will be unlikely to
jump clear and the machine may crush you.
T133803 —UN—27SEP00
Use seat belt at all times.
T133716 —19—17APR13
Avoid Machine Tip Over
TX03679,00016DF -19-03JAN07-1/1
1-3-3
080913
PN=18
Safety—Operating Precautions
Use Special Care When Lifting Objects
T133839 —UN—27SEP00
Never use this machine to lift people.
Never lift a load above another person. Keep bystanders
clear of all areas where a load might fall if it breaks free.
Do not leave the seat when there is a raised load.
Do not exceed lift capacity limits posted on machine and
in this manual. Extending heavy loads too far or swinging
over undercarriage side may cause machine to tip over.
Use proper rigging to attach and stabilize loads. Be sure
slings or chains have adequate capacity and are in good
condition. Use tether lines to guide loads and prearranged
hand signals to communicate with co-workers.
TX03679,00016E1 -19-03JAN07-1/1
Add and Operate Attachments Safely
Always verify compatibility of attachments by contacting
your authorized dealer. Adding unapproved attachments
may affect machine stability or reliability and may create a
hazard for others near the machine.
Ensure that a qualified person is involved in attachment
installation. Add guards to machine if operator protection
is required or recommended. Verify that all connections
are secure and attachment responds properly to controls.
Carefully read attachment manual and follow all
instructions and warnings. In an area free of bystanders
and obstructions, carefully operate attachment to learn its
characteristics and range of motion.
TX03679,00016F0 -19-12FEB07-1/1
1-3-4
080913
PN=19
Safety—Maintenance Precautions
Park and Prepare for Service Safely
Warn others of service work. Always park and prepare
your machine for service or repair properly.
and attachments to the ground.
• Place pilot shutoff lever in “lock” position. Stop engine
and remove key.
• Attach a “Do Not Operate” tag in an obvious place in
the operator's station.
Securely support machine or attachment before working
under it.
T133332 —19—17APR13
• Park machine on a level surface and lower equipment
• Do not support machine with boom, arm, or other
hydraulically actuated attachments.
• Do not support machine with cinder blocks or wooden
pieces that may crumble or crush.
• Do not support machine with a single jack or other
Understand service procedures before beginning repairs.
Keep service area clean and dry. Use two people
whenever the engine must be running for service work.
TS229 —UN—23AUG88
devices that may slip out of place.
TX03679,00016E9 -19-03JAN07-1/1
Service Cooling System Safely
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
to relieve pressure before removing completely.
TS281 —UN—15APR13
Explosive release of fluids from pressurized cooling
system can cause serious burns.
DX,RCAP -19-04JUN90-1/1
1-4-1
080913
PN=20
Safety—Maintenance Precautions
Remove Paint Before Welding or Heating
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch.
TS220 —UN—15APR13
Remove paint before heating:
• Remove paint a minimum of 100 mm (4 in.) from area
•
•
to be affected by heating. If paint cannot be removed,
wear an approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
Do not use a chlorinated solvent in areas where welding
will take place.
Do all work in an area that is well ventilated to carry toxic
fumes and dust away.
Dispose of paint and solvent properly.
DX,PAINT -19-24JUL02-1/1
Make Welding Repairs Safely
Avoid welding or heating near pressurized fluid lines.
Flammable spray may result and cause severe burns if
pressurized lines fail as a result of heating. Do not let heat
go beyond work area to nearby pressurized lines.
Remove paint properly. Do not inhale paint dust or fumes.
Use a qualified welding technician for structural repairs.
T133547 —UN—15APR13
IMPORTANT: Disable electrical power before
welding. Turn off main battery switch
or disconnect positive battery cable.
Separate harness connectors to engine and
vehicle microprocessors.
Make sure there is good ventilation. Wear eye protection
and protective equipment when welding.
OUO1032,00015DD -19-06OCT09-1/1
Always wear protective goggles or safety glasses and
other protective equipment before striking hardened
parts. Hammering hardened metal parts such as pins and
bucket teeth may dislodge chips at high velocity.
Use a soft hammer or a brass bar between hammer and
object to prevent chipping.
T133738 —UN—15APR13
Drive Metal Pins Safely
TX03679,0001745 -19-03JAN07-1/1
1-4-2
080913
PN=21
Safety—Safety Signs
T205161 —19—21DEC04
Safety Signs
Continued on next page
1-5-1
MM61211,0000A6B -19-25JAN08-1/2
080913
PN=22
T217441 —19—11JUL06
Safety—Safety Signs
MM61211,0000A6B -19-25JAN08-2/2
1-5-2
080913
PN=23
Operation—Operator Station
Monitor Panel and Functions (S.N. —255551)
1. Coolant Temperature Gauge: When the first three
segments come ON, the coolant temperature is normal.
NOTE: When the coolant temperature is lower than
20°C (68°F), the first segment will flash.
2. Fuel Gauge and Fuel Level Indicator: When the fuel
level is low, the first segment flashes, indicating the fuel
tank is almost empty. Add fuel before gauge reaches “E.”
NOTE: When the key switch is OFF, continuously
pressing display select switch (5) for more than
0.5 seconds will display the fuel level.
T216977 —UN—04NOV05
3. Monitor Display: Three modes are available: hour
meter, trip meter 1 and trip meter 2. To change mode,
press DISPLAY SELECT switch (5) until desired mode
is displayed. Hour meter is the default display. The
right-hand number on the hour meter indicates tenths of
an hour (six minutes).
4. SET Switch: Used to set trip meters.
5. DISPLAY SELECT Switch: Used to change
information shown in monitor display.
6. Fast Travel Mode Indicator: When fast travel mode is
selected on travel speed control switch, fast travel mode
indicator will light.
7. Engine PreHeat Indicator: Yellow indicator will light
when key switch is held in the HEAT position. Indicator
will go out after 15 seconds, indicating that preheating is
completed. Start engine immediately after light goes out.
8. Alternator Voltage Indicator: Indicator will light with
no or low alternator output.
9. Low Fuel Level Indicator: When the fuel level
indicator flashes while machine is operating on level
ground, fuel level is extremely low (approximately 6.5 L
[1.7 gal]). Refuel as soon as possible.
10. Engine Coolant Temperature Gauge and Engine
Coolant Temperature Indicator: Coolant temperature is
normal when the gauge segments remain in the white
range.
The monitor alarm sounds and the gauge segments in
the red range come ON when coolant temperature rises
extremely high. Reduce load immediately and run engine
at slow idle. Inspect for debris around radiator. Check for
low coolant in the radiator recovery tank.
1— Coolant Temperature
Gauge
2— Fuel Gauge
3— Monitor Display
4— SET Switch
5— DISPLAY SELECT Switch
6— Fast Travel Mode Indicator
7— Engine Preheat Indicator
8— Alternator Voltage Indicator
9— Low Fuel Level Indicator
10— High Coolant Temperature
Indicator
11— Engine Oil Pressure
Indicator
12— System Failure Indicator
11. Engine Oil Pressure Indicator:
IMPORTANT: Avoid engine damage. If engine oil
pressure light comes on while operating,
stop engine immediately.
Indicator will light and alarm will sound when engine oil
pressure is low. Stop engine immediately.
NOTE: Cold oil, low oil level, or extreme off-level
operation may cause indicator to light.
12. System Failure Indicator: The indicator will come
ON or flash when an abnormality is found in the system.
Contact your authorized dealer as soon as possible.
MB60223,00002CD -19-29AUG12-1/1
2-1-1
080913
PN=24
Operation—Operator Station
Monitor Panel and Functions (S.N. 255551— )
1. Coolant Temperature Gauge:
When the first three segments are illuminated, the coolant
temperature is normal.
NOTE: When the coolant temperature is lower than
20°C (68°F), the first segment flashes.
2. Fuel Gauge:
Position of segment illumination indicates fuel level. Add
fuel before only the “E” segment of the gauge is illuminated
and/or the Low Fuel Level Indicator (5) is illuminated.
3. Hour Meter:
Numbers to the left of the decimal point indicate total
accumulated operation hours since the machine began
working. The number to the right of the decimal point
indicates tenths of an hour (six minutes).
4. Overheat Indicator:
If the temperature of the coolant is extremely hot, this
indicator illuminates and a buzzer activates. Immediately
stop machine operation and reduce engine speed to slow
idle speed to reduce coolant temperature.
5. Low Fuel Level Indicator:
If this indicator illuminates while on level ground, the
amount of fuel remaining in the fuel tank is 10.0 L (2.6 gal)
or less. Add fuel to the fuel tank as soon as safely possible.
6. Alternator Indicator:
This indicator illuminates when little or no alternator output
exists. If this indicator illuminates, examine components of
the electrical system such as the alternator and/or battery.
7. Auto Idle Indicator:
This indicator illuminates when the auto-idle switch on
the switch panel is activated.
8. Fast Travel Mode Indicator:
This indicator illuminates when the fast mode side (rabbit)
of the travel mode switch has been pressed.
9. System Failure Indicator:
This indicator will illuminate and/or flash when there is a
strong possibility of an irregularity in the engine control
system.
TX1096536A —UN—25AUG11
IMPORTANT: Avoid machine damage. If all
segments of the fuel gauge are illuminated
and flashing, immediately contact your
authorized John Deere dealer.
Monitor Panel (S.N. 280539— )
1— Coolant Temperature
Gauge
2— Fuel Gauge
3— Hour Meter
4— Overheat Indicator
5— Low Fuel Level Indicator
6— Alternator Indicator
7— Auto Idle Indicator
8— Fast Travel Mode Indicator
9— System Failure Indicator
10— Preheat Indicator
11— Engine Oil Pressure
Indicator
IMPORTANT: Avoid machine damage. If system
failure indicator is illuminated, contact your
authorized John Deere dealer immediately.
10. Preheat Indicator:
This indicator illuminates when the machine determines
that preheating is required.
11. Engine Oil Pressure Indicator:
This indicator illuminates red when low engine oil pressure
is present. The engine oil pressure warning buzzer
activates simultaneously with indicator.
IMPORTANT: Avoid machine damage. If engine oil
pressure indicator is illuminated, stop the
engine immediately. Examine the engine
oil pressure system and engine oil level for
the presence of irregularities.
MB60223,00002CE -19-29AUG12-1/1
2-1-2
080913
PN=25
Operation—Operator Station
Switch Panel—Cab
1. Work Light Switch: Press the upper half of switch to
turn work lights ON. Press the lower half of switch to turn
work lights OFF.
T216978 —UN—04NOV05
2. Travel Speed Control Switch: Press the upper half
of switch (rabbit) to select the fast travel mode. As load
increases, travel speed decreases. Press the lower half
of switch (turtle) to select slow travel mode.
3. Wiper and Washer Switch: Push switch to operate
wiper continuously. Press and hold down switch to
activate washer.
NOTE: Make sure the upper front window is fully
secure. Wiper will not operate if window is
not in proper position.
Cab Machines
4. Travel Alarm Cancel Switch: The travel alarm sounds
when a travel lever is operated and will continue as long
as the tracks are moving. When travel motion stops, the
travel alarm switch is reset. Press the travel alarm cancel
switch to shut alarm off.
5. Upper Vent and Defrost Button: Push button to direct
air flow to upper vents and upper front window.
6. Upper and Lower Vents and Defrost Button: Push
button to direct air flow to upper and lower vents and
upper front window.
7. Lower Vent Button: Push button to direct air flow to
lower vents.
8. Air Conditioner ON/OFF Button: Push button to turn
air conditioning ON. Indicator will light. Push button again
to turn air conditioning OFF. Heating and air conditioner
power button (12) must also be ON.
9. Temperature Control—Lower Button: Push button
to lower temperature.
1— Work Light Switch
2— Travel Speed Control
Switch
3— Wiper and Washer Switch
4— Travel Alarm Cancel Switch
5— Upper Vent and Defrost
Button
6— Upper and Lower Vents and
Defrost Button
7— Lower Vent Button
8— Air Conditioner ON/OFF
Button
9— Temperature Control—Lower Button
10— Temperature Control—Raise Button
11— Blower Speed Button
12— Heater and Air Conditioner
Power Button
11. Blower Speed Buttons: Push upper button to
increase blower speed. Push lower button to decrease
blower speed.
12. Heater and Air Conditioner Power Button: Push
button to turn power to heater ON or OFF. Indicator above
button will light when power is ON. Push button again to
turn heater OFF. To operate air conditioning, heater and
air conditioner power button and air conditioner ON/OFF
button (8) must be on.
10. Temperature Control—Raise Button: Push button
to raise temperature.
MM61211,0000976 -19-13DEC05-1/1
2-1-3
080913
PN=26
Operation—Operator Station
Switch Panel—Canopy
1. Work Light Switch: Press the upper half of switch to
turn work lights ON. Press the lower half of switch to turn
work lights OFF.
T216979 —UN—04NOV05
2. Travel Speed Control Switch: Press the upper half
of switch (rabbit) to select the fast travel mode. As load
increases, travel speed decreases. Press the lower half
of switch (turtle) to select slow travel mode.
3. Travel Alarm Cancel Switch: The travel alarm sounds
when a travel lever is operated and will continue as long
as the tracks are moving. When travel motion stops, the
travel alarm switch is reset. Press the travel alarm cancel
switch to shut alarm off.
1— Work Light Switch
2— Travel Speed Control
Switch
3— Travel Alarm Cancel Switch
Canopy Machines
MM61211,0000977 -19-03NOV05-1/1
Pedals and Levers
6— Right Control Lever/Horn
(located on top of lever)
7— Blade Control Lever
8— Pilot Control Shutoff Lever
9— Engine Speed Control
Lever
T216986A —UN—07NOV05
1— Left Control Lever
2— Auxiliary Pedal—If
Equipped
3— Left Travel Lever
4— Right Travel Lever
5— Boom Swing Pedal
MM61211,0000979 -19-13DEC05-1/1
Engine Speed Control Lever
Use the engine speed control lever (1) to adjust engine
speed.
Pull lever back to increase speed.
Push lever forward to decrease speed.
T216987A —UN—07NOV05
1— Engine Speed Control
Lever
MM61211,000097A -19-04NOV05-1/1
2-1-4
080913
PN=27
Operation—Operator Station
Pilot Control Shutoff Lever
T204913 —UN—03DEC04
The pilot control shutoff lever (1) shuts off hydraulic pilot
pressure to all pilot control valves. When pilot control
shutoff lever is in locked (up) position, the machine will
not move if a pilot control lever (3) or pedal is accidentally
moved.
IMPORTANT: Prevent possible console or control
lever damage. Only use the pilot control shutoff
lever to raise or lower console (2).
Pilot control shutoff lever is linked to the console latch
mechanism. Raise and lower console using pilot control
shutoff lever.
Always pull pilot control shutoff lever up to locked position
when stopping the engine or leaving the operator’s station.
NOTE: After moving pilot control shutoff lever to
unlocked position, check that no activators
move when all control levers and pedals are in
neutral before starting operation.
Locked Position Shown
1— Pilot Control Shutoff Lever
2— Console
3— Pilot Control Lever
Engine will not start unless pilot control shutoff lever is in
locked position. Slowly lower lever to unlocked position
before starting operation.
OU90V02,0000142 -19-06JAN09-1/1
2-1-5
080913
PN=28
Operation—Operator Station
Setting Trip Meters
NOTE: Trip meters are preset to 10,000 hours
at the factory.
Trip meters can be set to notify the operator that a certain
number of operation hours have passed. There are
two meters, TRIP 1 and TRIP 2, and each one is set
individually.
To Set Trip Meters
2. Press DISPLAY SELECT switch (1) to display either
trip meter 1 (3) or trip meter 2 (4).
3. Press SET switch (2) to select number of hours. The
available hour settings are:
T205888 —UN—07DEC04
• 50
• 100
• 150
• 200
• 250
• 300
• 400
• 500
• 750
• 1000
• 1250
• 1500
• 2000
• 2500
• 3000
T216988 —UN—07NOV05
1. Turn key switch ON.
5. When set hours reach zero, the trip meter display
will flash. If trip meter is not reset at that time, the
trip meter hours will continue to display the operation
hours with a minus (-) sign until trip meter is reset.
1— DISPLAY SELECT Switch
2— SET Switch
3— TRIP 1 (trip meter 1)
4— TRIP 2 (trip meter 2)
T205889 —UN—07DEC04
4. Press DISPLAY SELECT switch (1) to set the trip
meter hours.
MM61211,000097B -19-13DEC05-1/1
2-1-6
080913
PN=29
Operation—Operator Station
IMPORTANT: Prevent machine damage from
swinging door. Ensure door is latched
securely in both outer latches (1 and 2) if
operating with door open.
The cab door can be locked in the open position. Open
the door all the way until it locks in both latches (1 and 2)
on the side of the cab.
To release the door from locked position, push down on
door release lever (3).
3— Door Release Lever
T204914 —UN—21DEC04
1— Outer Latch
2— Outer Latch
T205343 —UN—09DEC04
Door Release Lever—If Equipped
OUO1032,0001572 -19-16NOV04-1/1
2-1-7
080913
PN=30
Operation—Operator Station
Front (Secondary Exit) Window—If Equipped
Open
2. Grasp the handholds (2).
CAUTION: Prevent possible injury from
unexpected rapid window movement. Ensure
cab frame lock pins (3) are fully engaged.
3. Pull window up and back until the frame lock pins (3)
latch into the cab frame boss holes.
T205344 —UN—09DEC04
1. Pull lock pins (1) down to release window.
CAUTION: Prevent possible injury from
unexpected rapid window movement. Front
window can come down forcefully. Close
window only when sitting on operator’s seat.
Guide window down slowly.
1. Unlatch cab frame lock pins from cab frame boss holes.
2. Slide window down slowly using handholds.
T205345 —UN—09DEC04
Close
3. Push on handholds until window lock pins (1) are
locked in place.
3— Cab Frame Lock Pin (2
used)
T205346 —UN—09DEC04
1— Window Lock Pin (2 used)
2— Handhold (2 used)
MM61211,0000A63 -19-07DEC05-1/1
2-1-8
080913
PN=31
Operation—Operator Station
Secondary Exit Tool—If Equipped
NOTE: Use tool (1) to break window. Always
keep tool in machine.
T204915 —UN—03DEC04
If the cab door does not open, exit in the following manner:
1. Open the front window. Exit through the window.
CAUTION: Protect your eyes and face from
broken glass and debris.
2. If the front window is difficult to open, break the
window glass with the secondary exit tool (1). Exit
through the broken window.
1— Secondary Exit Tool
3. If exiting through the front window is not possible,
break the rear window glass with the secondary exit
tool. Exit through the broken window.
NOTE: A secondary exit kit is also offered through
your authorized dealer.
OUO1032,0001573 -19-16NOV04-1/1
Opening Rear Window—If Equipped
Lift up on latches (1) to unlock. Push latch joints to open
window. Lock latches in place.
T122095 —UN—30JUN99
1— Rear Window Latch (2 used)
CED,TX14740,6400 -19-07MAY99-1/1
Opening Right Side Window—If Equipped
T122098 —UN—30JUN99
Slide front pane to the rear and/or rear pane to the front to
open and/or close the window.
CED,TX14740,6439 -19-11JUN99-1/1
2-1-9
080913
PN=32
Operation—Operator Station
Adjusting Operator Seat
Move lever (1) to the right and hold to slide the seat
forward or rearward. Release lever to lock.
T204918 —UN—03DEC04
1— Seat Fore-Aft Adjustment
OUO1032,0001574 -19-16NOV04-1/1
Toolbox and Operator’s Manual
Compartment
Store operator’s manual in compartment (2) behind the
seat.
T216989 —UN—08NOV05
2— Operator’s Manual
Compartment
Canopy Machines
T217413 —UN—08DEC05
1— Tool Box—Canopy
Machines
MM61211,000097C -19-04NOV05-1/1
2-1-10
080913
PN=33
Operation—Operating the Machine
Before Starting Work
T133556 —UN—24AUG00
Review the operating precautions. See
Safety-Operating Precautions. (Section 1-3.)
Use seat belt when operating machine. Remember to
fasten seat belt even during brief periods of use.
Reading Operator's Manual
TX03679,0001780 -19-21AUG12-1/1
Operator's Daily Machine Check Before
Starting
Safety and Protective Devices Checks
Walk around machine to clear all persons from machine
area before starting machine.
Check condition of guards, shields, and covers.
Overall Machine Checks
Check for worn or frayed electrical wires and loose or
corroded connections.
Check for bent, broken, loose, or missing boom, bucket,
sheet metal, track parts.
Check for loose or missing hardware.
1— Check Pedal and Lever
Movement, clean cab of
any debris
2— Check Hydraulic Tank Oil
Level
3— Check Coolant Recovery
Tank Level
4— Check/Clean Radiator and
Oil Cooler Outer Fins
5— Check Engine Oil Level
T123629 —UN—17AUG99
Check for oil leaks, missing or loose hose clamps, kinked
hoses, and lines or hoses that rub against each other or
other parts.
MM61211,0000A6D -19-18APR06-1/1
2-2-1
080913
PN=34
Operation—Operating the Machine
Starting the Engine
NOTE: Engine will not start unless pilot control shut-off
lever is in locked (rearward) position.
T204921 —UN—03DEC04
1. Turn the key switch to ON (3).
2. Sound horn to alert persons nearby.
3. Move the engine speed control lever to slow idle.
IMPORTANT: Prevent starter damage. Never
operate starter for more than 15 seconds at
a time. If engine fails to start, return key
switch to OFF. Wait about 30 seconds, then
try again. After a false start, do not turn
key switch until engine stops.
1— HEAT
2— OFF
3— ON
4— START
4. Turn key switch to START (4). Release key; switch
will return to ON position.
MM61211,0000A65 -19-07DEC05-1/1
2-2-2
080913
PN=35
Operation—Operating the Machine
Starting the Engine in Cold Weather
Starting fluid is highly flammable; DO NOT
use any type of starting fluid. An electric air
preheater may ignite starting fluid.
IMPORTANT: DO NOT use ether or any other type
of starting fluid on engines equipped with
an electric preheater system.
T204921 —UN—03DEC04
CAUTION: Avoid injury! Prevent injury
from an explosion:
In extremely cold climates, set the engine
control lever (5) to the fast idle position to start
engine. After the engine is started, gradually
reduce engine speed and perform warm-up
procedure at the medium speed range.
1. Move engine speed control lever (5) halfway between
slow and fast idle in cold weather.
2. Turn and hold the key switch in HEAT position (1).
In cold weather the engine preheat indicator (6) on
monitor will light.
3. Sound horn to alert persons nearby.
T217414 —UN—08DEC05
NOTE: Engine will not start unless pilot control shutoff
lever is in locked (rearward) position.
4. When the engine preheat indicator light (6) goes out
after 15 seconds, immediately turn key switch to
START (4). Release key; switch will return to ON (3)
position.
5. Allow sufficient time for warm-up operation to be
completed.
1— HEAT
2— OFF
3— ON
4— START
5— Engine Speed Control
Lever
6— Preheat Indicator
T217415 —UN—08DEC05
IMPORTANT: Prevent starter damage. Never
operate starter for more than 15 seconds at
a time. If engine fails to start, return key
switch to OFF. Wait about 30 seconds, then
try again. After a false start, do not turn
key switch until engine stops.
DW90712,000018E -19-06JUL06-1/1
2-2-3
080913
PN=36
Operation—Operating the Machine
Checking Instruments After Starting
IMPORTANT: Prevent possible damage to engine.
If indicator lights do not go out after starting
engine, IMMEDIATELY STOP THE ENGINE.
Find and correct the problem.
After the engine is started, the alternator indicator light
(3) and engine oil pressure indicator light (2) should go
out. If they do not, stop the engine immediately. Find and
correct the problem.
1— Engine Coolant
Temperature Gauge
2— Engine Oil Pressure
Indicator
T216991 —UN—08NOV05
Engine coolant temperature gauge (1) should be in the
white zone.
3— Alternator Indicator
MM61211,000097D -19-18APR06-1/1
Cold Weather Warm-Up
CAUTION: Prevent possible injury from
unexpected machine movement. If hydraulic oil
is cold, hydraulic functions move slowly. DO NOT
attempt normal machine operation until hydraulic
functions move at close-to-normal cycle times.
In extremely cold conditions, an extended warm-up period
will be necessary. Under such conditions, the radiator and
oil cooler should be covered to maintain correct operating
temperature.
Avoid sudden operation of all functions until the engine
and hydraulic oil are thoroughly warm.
1. Run engine at 1/2 speed for 5 minutes. Do not run
at fast or slow idle.
CAUTION: Prevent possible injury from
unexpected machine movement. Clear the area of
all persons before running your machine through
the warm-up procedure. If machine is inside a
building, warm the travel circuit first and move
the machine to a clear area outside. Cold oil will
cause machine functions to respond slowly.
2. Exercise travel and swing functions slowly, initially
moving for only short distances.
3. Operate boom, arm, and bucket functions by moving
cylinders a short distance in each direction for the
first time.
4. Continue cycling cylinders by increasing cylinder
extension until full stroke is obtained.
IMPORTANT: Holding function actuated for more
than 30 seconds can cause damage from
hot spots in the control valve.
5. Actuate bucket curl function (cylinder extend) for 10
seconds and release for 5 seconds for a period of
2-1/2 minutes.
6. Repeat procedure with bucket dump function.
7. Operate all hydraulic functions to distribute warm oil
in all cylinders, motors, and lines.
8. If hydraulic functions still move slowly, repeat steps
5 and 6.
DW90712,0000105 -19-18APR06-1/1
2-2-4
080913
PN=37
Operation—Operating the Machine
Travel Pedals and Levers
T204926 —UN—07DEC04
CAUTION: Prevent possible injury from
unexpected machine movement. Keep
bystanders clear of machine when traveling.
The instructions below apply when the upperstructure is
facing forward and travel motors are to the rear of the
machine. If the upperstructure is rotated to the rear and
the travel motors are to the front of the machine, the
machine moves OPPOSITE to the direction described.
NOTE: Unfold foot pedals before using.
FORWARD TRAVEL: Push down on front (1) of both
pedals or push both levers forward (1).
T204927 —UN—07DEC04
REVERSE TRAVEL: Push down on rear (3) of both pedals
or pull both levers rearward (3).
NEUTRAL POSITION (2): Travel brakes will automatically
stop and hold the machine.
RIGHT TURN: Push down on front of left pedal or push
left lever forward.
LEFT TURN: Push down on front of right pedal or push
right lever forward.
SHORT TURN (COUNTER-ROTATE): Push down the
front of one pedal and the rear of the other or push one
lever forward and pull the other rearward.
CAUTION: Prevent possible injury from machine
tipping. Operate control pedals or levers slowly
when traveling down a slope.
TRAVELING DOWN A SLOPE: Operate control pedals or
levers slowly when traveling down a slope.
1— Forward Travel
2— Neutral Position
3— Reverse Travel
COLD WEATHER OPERATION: Travel pedal and lever
dampers are provided for smooth control. In extremely
cold weather, pedal or lever effort will increase. Operate
pedals or levers several times with pilot control shutoff
lever in locked position.
MM61211,0000A59 -19-13DEC05-1/1
2-2-5
080913
PN=38
Operation—Operating the Machine
Control Lever Pattern Operation
CAUTION: Never place any part of body beyond
the operator station to avoid serious crushing
injury from boom. Boom could lower if the
control lever is accidentally bumped or otherwise
engaged. Immediately replace a missing or
broken window (if equipped).
Never place any part of the body beyond the operator
station. Replace missing or broken windows (if equipped)
immediately.
T216992 —UN—08NOV05
CAUTION: Prevent injury from unexpected control
lever function. Be aware of the control lever
pattern used on the machine before operating.
A label showing each control lever pattern operation is
provided on the operator's right.
Check the pattern on the label and then carefully operate
the machine to verify that the selected pattern is correct.
(See Control Lever Pattern Conversion in this section.)
Excavator Control Lever Pattern
Control levers return to neutral when released. Functions
will stop and remain positioned. The parking brake for
swing and travel will also engage.
T216993 —UN—08NOV05
5— Boom Down
6— Boom Up
7— Bucket Load
8— Bucket Dump
Backhoe Control Lever Pattern
T204931 —UN—07DEC04
1— Arm Out
2— Arm In
3— Swing Left
4— Swing Right
Boom, Arm, Bucket Movement
MM61211,000097F -19-13DEC05-1/1
2-2-6
080913
PN=39
Operation—Operating the Machine
Control Lever Pattern Conversion
The machine pilot control levers can be changed from
the standard “Excavator” control pattern to a “Backhoe”
control pattern. To change control pattern:
T205091 —UN—01DEC04
1. Park machine on a level surface.
2. Run engine at slow idle speed without load for 3
minutes.
3. Turn key switch to OFF to stop engine. Remove key
from switch.
4. Pull pilot shutoff lever up to the locked position.
5. Selector lever (1) is located under seat. Open panel
to access selector lever.
6. Rotate selector lever to desired control pattern position.
(Lever must be aligned with arrow on selected control
pattern and detented in order to function as expected.)
1— Control Pattern Selector
Lever
2— Excavator Position
3— Backhoe Position
8. Verify selected pattern is visible through sight hole.
7. Close panel.
OUO1032,000159D -19-25JAN07-1/1
Multi-Function Control Lever—If Equipped
TX1054235 —UN—09JAN09
1. Move slide switch (2) of multi-function right control
lever (1) to the right or left to operate front-end
attachment such as hydraulic breaker.
2. When switch (3) of right control lever is pushed, it
operates the same as when slide switch is moved to
the left. (This switch operation is convenient for using
hydraulic breaker.)
In case slide switch and switch are pushed simultaneously,
switch operation has priority.
3— Switch
2
1
1
3
TX1054236 —UN—09JAN09
1— Multi-Function Right
Control Lever
2— Slide Switch
OU90V02,000014A -19-09JAN09-1/1
2-2-7
080913
PN=40
Operation—Operating the Machine
Boom-Swing Pedal
T216995 —UN—08NOV05
CAUTION: Avoid injury from unexpected machine
movement. Keep boom-swing pedal locked
during travel and when not in use.
1. Lift pedal cover (2) to unlock boom-swing pedal (1).
2. Push on left side of pedal to swing left (3).
3. Push on right side of pedal to swing right (4).
4. Lower pedal cover to lock boom-swing pedal when
not in use.
3— Swing Left
4— Swing Right
T216996 —UN—08NOV05
1— Boom-Swing Pedal
2— Pedal Cover
Unlocked Position
T120779 —UN—14APR99
Locked Position
MM61211,0000980 -19-04NOV05-1/1
Auxiliary Pedal
T204935 —UN—07DEC04
CAUTION: Avoid injury from unexpected machine
movement. Keep pedal cover in locked position
when not using auxiliary pedal.
1. Lift pedal cover (1) to unlock auxiliary pedal (2).
2. Push on the right or left side of the auxiliary pedal to
operate the front-end attachment. (See Positioning
Auxiliary Line Selector Valve below for single and
double activation.)
3. Lower pedal cover to lock auxiliary pedal.
1— Pedal Cover
2— Auxiliary Pedal
OUO1032,000157B -19-16NOV04-1/1
2-2-8
080913
PN=41
Operation—Operating the Machine
Positioning Auxiliary Line Selector Valve
IMPORTANT: Prevent possible machine damage.
Stop the engine and move pilot control shutoff
lever to locked (rearward) position before
moving the selector valve.
1. Park machine on a level surface.
2. Lower attachments to the ground.
4. Remove plug (1) to access selector valve. Selector
valve must be positioned according to the type of
attachment to be operated:
• Position 2:
1— Selector Valve Plug
2— OPEN/CLOSE (for double
actuating cylinder
attachment)
3— ON/OFF (for single
actuating cylinder
attachment)
T205137A —UN—10DEC04
•
Operating a crusher or other double
actuating cylinder attachment requiring two actions
such as OPEN/CLOSE operation.
Position 3: Operating a breaker or other single
actuating cylinder attachment requiring only ON/OFF
operation.
T216997 —UN—08NOV05
3. Stop engine.
MM61211,0000981 -19-13DEC05-1/1
2-2-9
080913
PN=42
Operation—Operating the Machine
Operating Backfill Blade
Pull blade lever (1) rearward to raise blade (2).
Push blade lever forward to lower blade (3).
3— Blade Lower
T205092 —UN—01DEC04
1— Blade Lever
2— Blade Raise
T216998 —UN—08NOV05
When the blade lever is released, it automatically returns
to neutral, keeping the blade in position until the lever is
moved again.
MM61211,0000982 -19-04NOV05-1/1
• Do not use blade to dig.
• Do not run the machine into a load.
• Lower the blade to the ground.
Operating Tips—Backfill Blade
• Use blade only for moving loose material and for
backfilling.
• Load the blade evenly.
MM61211,0000A66 -19-07DEC05-1/1
2-2-10
080913
PN=43
Operation—Operating the Machine
Operating in Water and Mud
Be careful not to operate the machine in water or mud
above the upper track shoe surface (1), causing the swing
bearing and rotary manifold to be submerged.
T121704 —UN—08JUN99
Specification
Upper Track Shoe
Surface (Operable Water
Depth)—Distance........................................................................ 485 mm
19 in.
If the swing bearing and rotary manifold are submerged,
remove cover from underneath center of machine.
Remove drain plug to drain water and mud.
Clean swing gear area. Install plug and cover. Grease
swing bearing and grease swing bearing gear. (See
Sections 3-6 and 3-7.)
1— Upper Track Shoe Surface
MM61211,0000983 -19-13DEC05-1/1
Selecting Correct Track
IMPORTANT: Avoid damaging tracks. Using rubber
tracks or rubber pads on rough ground may
result in pads being damaged.
Rubber tracks and rubber pads are designed for flat, hard
surfaces only. Do not use on rough ground such as rocks,
sand or gravel.
Check track shoe bolts periodically for tightness.
OUO1032,00015DF -19-25JAN07-1/1
Driving Up a Steep or Slippery Slope
CAUTION: Prevent possible injury from machine
rollover. Use this technique only on a short slope.
Machine depends on support of boom/arm/bucket
during entire procedure until machine reaches
top of slope. Repositioning the bucket during
this procedure is NOT recommended. DO NOT
swing upperstructure during this procedure. DO
NOT reposition bucket during this procedure.
1. Wear seat belt.
2. Position undercarriage so travel motors will be on
uphill end of machine.
3. Push bucket into the ground.
4. When boom is on uphill end of machine: Pull machine
using boom and arm cylinder to help travel motors.
When boom is on downhill end of machine: Push
machine using boom and arm cylinder to help travel
motors.
DW90712,000018F -19-30JAN07-1/1
2-2-11
080913
PN=44
Operation—Operating the Machine
Lowering Boom With Engine Stopped
When the engine stops during operation, the boom cannot
be lowered using the pilot controller because there is no
pilot pressure to move the boom valve spool.
1.
1
Remove cover for access to boom up circuit relief
valve (1).
2. Make an alignment mark on the adjusting screw (2),
nut (3), and relief valve body.
3. Loosen nut using a 14 mm wrench.
P3
Loosening the boom up circuit relief valve
adjusting screw more than two turns may
result in the release of the pilot spring and
oil from the circuit relief valve.
T217139 —UN—16NOV05
CAUTION: Prevent possible injury from
unexpected machine movement. Clear all
persons from the area before lowering the boom.
T217139
4. Slowly turn the adjusting screw out approximately
1-1/2 turns to lower the boom.
5. After bucket is on the ground, turn the adjusting screw
in to its original setting. Hold the screw and tighten
the nut.
3— Nut
2
T217140
T217140 —UN—16NOV05
1— Boom Up Circuit Relief
Valve
2— Adjusting Screw
3
MM61211,00009F2 -19-18APR06-1/1
2-2-12
080913
PN=45
Operation—Operating the Machine
Parking
T204913 —UN—03DEC04
IMPORTANT: During freezing weather, prevent
damage to undercarriage components from
frozen mud and dirt. Machine must be
parked on a solid level surface to prevent
tracks freezing in the ground.
1. Park machine on a level surface.
2. Lower the bucket and blade to the ground.
3. Run engine at slow idle speed without load for 3
minutes.
Lever in Locked Position
4. Turn key switch to OFF. Remove key from switch.
5. Pull pilot control shutoff lever (1) to locked position.
1— Pilot Control Shut-Off Lever
2— Console
3— Pilot Control Levers
6. Close windows and cab door, if equipped.
7. Lock all access doors and compartments.
OUO1032,000157E -19-25JAN07-1/1
Loading and Unloading for Transport
CAUTION: Avoid possible injury from unexpected
machine movement. Use extra care to prevent tip
over or unexpected movement when loading and
unloading machine for transport. Observe these
rules when loading and unloading machine:
T217416 —UN—08DEC05
• Always wear seat belt.
• Locate trailer on a level and stable surface.
Chock trailer wheels.
Keep ramps at a low
angle and firmly attached to trailer.
• Use loading ramps.
1. When loading machine, use bucket for support with
angle of arm to boom at 90°.
IMPORTANT: Prevent machine or trailer damage. DO
NOT allow machine or bucket to impact trailer.
2. Position machine on trailer (centerline of machine over
centerline of trailer).
4. When unloading machine, use bucket for support with
angle of arm to boom at 90°.
3. Lower the bucket and fasten machine to trailer at the
blade and track frame. Do not allow cables to come
into direct contact with rubber tracks.
MM61211,0000A67 -19-13DEC05-1/1
2-2-13
080913
PN=46
Operation—Operating the Machine
Towing Machine a Short Distance
T121986 —UN—24JUN99
CAUTION: Prevent possible injury from tow
line breaking. Do not tow machine with
damaged chains, frayed cables, slings,
straps or wire tow lines.
Always wear gloves when handling cables,
straps, or wire tow lines.
Attach tow line to track frame of machine being towed,
and of towing machine. Slowly tow machine.
MM61211,0000A6E -19-13DEC05-1/1
Lifting
2. Without bucket loop: Curl bucket and retract arm.
Fasten sling or chain to bucket pivot pin.
CAUTION: Prevent possible injury when
lifting. Observe these rules when lifting
with your machine:
• Never use machine to lift people.
• Do not exceed lift capacity limits.
• Keep everyone clear of raised loads.
• Never attach sling or chain to bucket teeth.
• Use tether lines to guide loads.
• Use hand signals to communicate with others.
1. Use proper rigging to attach and stabilize loads.
With bucket loop: Curl bucket and retract arm. Fasten
sling or chain to bucket loop.
3. Check stability by carefully doing a trial lift:
• Raise load just off the ground
• Swing load all the way to one side
• Move load slowly away from machine
• Lower load immediately if machine is not stable
MM61211,0000A6F -19-13DEC05-1/1
2-2-14
080913
PN=47
Operation—Operating the Machine
Lifting Machine
CAUTION: Prevent possible injury from
unexpected machine movement when lifting
the machine. Check lifting capacity of crane
before lifting the excavator. Lift load only
as high as necessary.
Keep all people clear of raised load.
1. Swing the upperstructure so the blade is positioned
to the rear.
2. Fully retract the blade cylinder.
3. Fully extend the boom, arm, and bucket cylinders.
4. Position the boom straight ahead of the upperstructure.
5. Turn key switch to OFF. Remove key from switch.
6. Pull the pilot control shut-off lever to the locked position.
T217418 —UN—12DEC05
7. Attach cables to the eye plates, one on the boom and
two on the blade.
8. Slowly lift the machine.
Specification
Excavator—Operating
Weight—Canopy......................................................................... 2800 kg
6160 lb
Operating
Weight—Cab .............................................................................. 2950 kg
6490 lb
Operating
Weight—Canopy,
Long Arm, Additional
Counterweight ............................................................................ 3010 kg
6620 lb
Operating Weight—Cab,
Long Arm, Additional
Counterweight ............................................................................ 3160 kg
6950 lb
1— Boom Eye
2— Blade Eye
MM61211,0000984 -19-04NOV05-1/1
2-2-15
080913
PN=48
Maintenance—Machine
Diesel Fuel
Consult your local fuel distributor for properties of the
diesel fuel available in your area.
In general, diesel fuels are blended to satisfy the low
temperature requirements of the geographical area in
which they are marketed.
Diesel fuels specified to EN 590 or ASTM D975 are
recommended. Renewable diesel fuel produced by
hydrotreating animal fats and vegetable oils is basically
identical to petroleum diesel fuel. Renewable diesel that
meets EN 590 or ASTM D975 is acceptable for use at all
percentage mixture levels.
Sulfur Content for Tier 3 and Stage III A Engines
• Use of diesel fuel with sulfur content less than 1000
mg/kg (1000 ppm) is RECOMMENDED
• Use of diesel fuel with sulfur content 1000–5000 mg/kg
(1000–5000 ppm) REDUCES oil and filter change
intervals.
• BEFORE using diesel fuel with sulfur content greater
than 5000 mg/kg (5000 ppm), contact your John Deere
dealer
Sulfur Content for Tier 2 and Stage II Engines
Required Fuel Properties
• Use of diesel fuel with sulfur content less than 500
In all cases, the fuel shall meet the following properties:
• Use of diesel fuel with sulfur content 500–5000 mg/kg
Cetane number of 43 minimum. Cetane number greater
than 47 is preferred, especially for temperatures below
–20°C (–4°F) or elevations above 1500 m (5000 ft.).
Cold Filter Plugging Point (CFPP) should be at least 5°C
(9°F) below the expected lowest temperature or Cloud
Point below the expected lowest ambient temperature.
Fuel lubricity should pass a maximum scar diameter of
0.45 mm as measured by ASTM D6079 or ISO 12156-1.
Diesel fuel quality and sulfur content must comply with
all existing emissions regulations for the area in which
the engine operates. DO NOT use diesel fuel with sulfur
content greater than 10 000 mg/kg (10 000 ppm).
Sulfur content for Interim Tier 4 and Stage III B engines
• Use ONLY ultra low sulfur diesel (ULSD) fuel with a
maximum of 15 mg/kg (15 ppm) sulfur content.
mg/kg (500 ppm) is RECOMMENDED.
•
(500–5000 ppm) REDUCES the oil and filter change
interval
BEFORE using diesel fuel with sulfur content greater
than 5000 mg/kg (5000 ppm), contact your John Deere
dealer
Sulfur Content for Other Engines
• Use of diesel fuel with sulfur content less than 5000
mg/kg (5000 ppm) is recommended.
• Use of diesel fuel with sulfur content greater than 5000
mg/kg (5000 ppm) REDUCES the oil and filter change
intervals.
IMPORTANT: Do not mix used diesel engine oil or any
other type of lubricating oil with diesel fuel.
IMPORTANT: Improper fuel additive usage may
cause damage on fuel injection equipment
of diesel engines.
DX,FUEL1 -19-11APR11-1/1
Lubricity of Diesel Fuel
Most diesel fuels manufactured in the United States,
Canada, and the European Union have adequate lubricity
to ensure proper operation and durability of fuel injection
system components. However, diesel fuels manufactured
in some areas of the world may lack the necessary lubricity.
If fuel of low or unknown lubricity is used, add John Deere
Fuel-Protect Diesel Fuel Conditioner (or equivalent) at
the specified concentration.
IMPORTANT: Make sure the diesel fuel used
in your machine demonstrates good
lubricity characteristics.
Fuel lubricity can improve significantly with biodiesel
blends up to B20 (20% biodiesel). Further increase in
lubricity is limited for biodiesel blends greater than B20.
Lubricity of Biodiesel Fuel
Fuel lubricity should pass a maximum scar diameter of
0.45 mm as measured by ASTM D6079 or ISO 12156-1.
DX,FUEL5 -19-14APR11-1/1
3-1-1
080913
PN=49
Maintenance—Machine
Handling and Storing Diesel Fuel
CAUTION: Reduce the risk of fire. Handle fuel
carefully. DO NOT fill the fuel tank when engine
is running. DO NOT smoke while you fill the
fuel tank or service the fuel system.
Fill the fuel tank at the end of each day's operation to
prevent water condensation and freezing during cold
weather.
Keep all storage tanks as full as practicable to minimize
condensation.
Ensure that all fuel tank caps and covers are installed
properly to prevent moisture from entering. Monitor water
content of the fuel regularly.
When using biodiesel fuel, the fuel filter may require more
frequent replacement due to premature plugging.
Check engine oil level daily prior to starting engine. A
rising oil level may indicate fuel dilution of the engine oil.
IMPORTANT: The fuel tank is vented through the
filler cap. If a new filler cap is required, always
replace it with an original vented cap.
When fuel is stored for an extended period or if there is a
slow turnover of fuel, add a fuel conditioner to stabilize the
fuel and prevent water condensation. Contact your fuel
supplier for recommendations.
DX,FUEL4 -19-14APR11-1/1
3-1-2
080913
PN=50
Maintenance—Machine
Biodiesel Fuel
Biodiesel fuel is comprised of mono-alkyl esters of long
chain fatty acids derived from vegetable oils or animal
fats. Biodiesel blends are biodiesel mixed with petroleum
diesel fuel on a volume basis.
The petroleum diesel portion of all biodiesel blends must
meet the requirements of ASTM D975 (US) or EN 590
(EU) commercial standards.
Biodiesel users in the U.S. are strongly encouraged to
purchase biodiesel blends from a BQ-9000 Certified
Marketer and sourced from a BQ-9000 Accredited
Producer (as certified by the National Biodiesel Board).
Certified Marketers and Accredited Producers can be
found at the following website: http://www.bq9000.org.
Before using fuel containing biodiesel, review the
Biodiesel Use Requirements and Recommendations in
this Operator’s Manual.
Environmental laws and regulations can encourage or
prohibit the use of biofuels. Operators should consult
with appropriate governmental authorities prior to using
biofuels.
All John Deere Engines with Exhaust Filter (Released
2011 and After)
While 5% blends (B5) are preferred, biodiesel
concentrations up to a 20% blend (B20) in petroleum
diesel fuel can be used. Biodiesel blends up to B20
can be used ONLY if the biodiesel (100% biodiesel or
B100) meets ASTM D6751, EN 14214, or equivalent
specification. Expect a 2% reduction in power and a 3%
reduction in fuel economy when using B20.
Biodiesel concentrations above B20 can harm the
engine’s emission control systems and should not be
used. Risks include, but are not limited to, more frequent
stationary regeneration, soot accumulation, and increased
intervals for ash removal.
Biodiesel contains residual ash. Ash levels exceeding the
maximums allowed in either ASTM D6751 or EN14214
can result in more rapid ash loading and require more
frequent cleaning of the Exhaust Filter (if present).
The fuel filter can require more frequent replacement,
when using biodiesel fuel, particularly if switching from
diesel. Check engine oil level daily prior to starting engine.
A rising oil level can indicate fuel dilution of the engine oil.
Biodiesel blends up to B20 must be used within 90 days
of the date of biodiesel manufacture. If used, biodiesel
blends above B20 must be used within 45 days from the
date of biodiesel manufacture.
When using biodiesel blends up to B20, the following
must be considered:
• Cold weather flow degradation
• Stability and storage issues (moisture absorption,
microbial growth)
John Deere approved fuel conditioners, which contain
detergent and dispersant additives, are required when
using B20, and are recommended when using lower
biodiesel blends.
• Possible filter restriction and plugging (usually a problem
when first switching to biodiesel on used engines.)
• Possible fuel leakage through seals and hoses
(primarily an issue with older engines)
All John Deere Engines Excluding Exhaust Filter
(Primarily Released Prior to 2012)
• Possible reduction of service life of engine components
Request a certificate of analysis from your fuel distributor
to ensure that the fuel is compliant with the specifications
provided in this Operator’s Manual.
While 5% blends (B5) are preferred, biodiesel
concentrations up to a 20% blend (B20) in petroleum
diesel fuel can be used. Biodiesel blends up to B20
can be used ONLY if the biodiesel (100% biodiesel or
B100) meets ASTM D6751, EN 14214, or equivalent
specification. Expect a 2% reduction in power and a 3%
reduction in fuel economy when using B20.
Consult your John Deere dealer for approved fuel
conditioners to improve storage and performance with
biodiesel fuels.
These John Deere engines can operate on biodiesel
blends above B20 (up to 100% biodiesel). Operate at
levels above B20 ONLY if the biodiesel is permitted by law
and meets the EN 14214 specification (primarily available
in Europe). Engines operating on biodiesel blends above
B20 might not fully comply with or be permitted by all
applicable emissions regulations. Expect up to a 12%
reduction in power and an 18% reduction in fuel economy
when using 100% biodiesel.
John Deere approved fuel conditioners, which contain
detergent and dispersant additives, are required when
using B20, and are recommended when using lower
biodiesel blends.
The following must also be considered if using biodiesel
blends above B20:
• Possible coking or blocked injector nozzles, resulting in
•
•
•
•
•
•
•
Biodiesel Use Requirements and Recommendations
power loss and engine misfire if John Deere approved
fuel conditioners are not used
Possible crankcase oil dilution (requiring more frequent
oil changes)
Possible lacquering or seizure of internal components
Possible formation of sludge and sediments
Possible thermal oxidation of fuel at elevated
temperatures
Possible compatibility issues with other materials
(including copper, lead, zinc, tin, brass, and bronze)
used in fuel handling equipment
Possible reduction in water separator efficiency
Possible damage to paint if exposed to biodiesel
Continued on next page
3-1-3
DX,FUEL7 -19-29AUG12-1/2
080913
PN=51
Maintenance—Machine
• Possible corrosion of fuel injection equipment
• Possible elastomeric seal and gasket material
degradation (primarily an issue with older engines)
• Possible high acid levels within fuel system
• Because biodiesel blends above B20 contain more
IMPORTANT: Raw pressed vegetable oils are
NOT acceptable for use as fuel in any
concentration in John Deere engines. Their
use could cause engine failure.
ash, using blends above B20 can result in more rapid
ash loading and require more frequent cleaning of the
Exhaust Filter (if present)
DX,FUEL7 -19-29AUG12-2/2
Testing Diesel Fuel
A fuel analysis program can help to monitor the quality
of diesel fuel. The fuel analysis can provide critical
data such as cetane number, fuel type, sulfur content,
water content, appearance, suitability for cold weather
operations, bacteria, cloud point, acid number, particulate
contamination, and whether the fuel meets specification.
Contact your John Deere dealer for more information on
diesel fuel analysis.
DX,FUEL6 -19-14APR11-1/1
3-1-4
080913
PN=52
Maintenance—Machine
Minimizing the Effect of Cold Weather on Diesel Engines
John Deere diesel engines are designed to operate
effectively in cold weather.
Diesel Fuel Flow Additive
However, for effective starting and cold weather operation,
a little extra care is necessary. The information below
outlines steps that can minimize the effect that cold
weather may have on starting and operation of your
engine. See your John Deere dealer for additional
information and local availability of cold weather aids.
Use John Deere Fuel-Protect Diesel Fuel Conditioner
(winter formula), which contains anti-gel chemistry, or
equivalent fuel conditioner to treat non-winter grade fuel
(No. 2-D in North America) during the cold weather
season. This generally extends operability to about 10°C
(18°F) below the fuel cloud point. For operability at even
lower temperatures, use winter grade fuel.
Use Winter Grade Fuel
When temperatures fall below 0°C (32°F), winter grade
fuel (No. 1-D in North America) is best suited for cold
weather operation. Winter grade fuel has a lower cloud
point and a lower pour point.
Cloud point is the temperature at which wax will begin to
form in the fuel and this wax causes fuel filters to plug.
Pour point is the lowest temperature at which movement
of the fuel is observed.
NOTE: On average, winter grade diesel fuel has a lower
Btu (heat content) rating. Using winter grade fuel
may reduce power and fuel efficiency, but should not
cause any other engine performance effects. Check
the grade of fuel being used before troubleshooting
for low power complaints in cold weather operation.
Air Intake Heater
An air intake heater is an available option for some
engines to aid cold weather starting.
Ether
An ether port on the intake is available to aid cold weather
starting.
CAUTION: Ether is highly flammable. Do not
use ether when starting an engine equipped
with glow plugs or an air intake heater.
IMPORTANT: Treat fuel when outside temperature
drops below 0°C (32°F). For best results, use
with untreated fuel. Follow all recommended
instructions on label.
BioDiesel
When operating with biodiesel blends, wax formation can
occur at warmer temperatures. Begin using John Deere
Fuel-Protect Diesel Fuel Conditioner (winter formula) at
5°C (41°F) to treat biodiesel fuels during the cold weather
season. Use B5 or lower blends at temperatures below
0°C (32°F). Use only winter grade petroleum diesel fuel
at temperatures below -10°C (14°F).
Winterfronts
Use of fabric, cardboard, or solid winterfronts is not
recommended with any John Deere engine. Their use
can result in excessive engine coolant, oil, and charge
air temperatures. This can lead to reduced engine life,
loss of power and poor fuel economy. Winterfronts may
also put abnormal stress on fan and fan drive components
potentially causing premature failures.
If winterfronts are used, they should never totally close
off the grill frontal area. Approximately 25% area in the
center of the grill should remain open at all times. At no
time should the air blockage device be applied directly
to the radiator core.
Radiator Shutters
Coolant Heater
An engine block heater (coolant heater) is an available
option to aid cold weather starting.
Seasonal Viscosity Oil and Proper Coolant
Concentration
Use seasonal grade viscosity engine oil based on the
expected air temperature range between oil changes
and a proper concentration of low silicate antifreeze as
recommended. (See DIESEL ENGINE OIL and ENGINE
COOLANT requirements in this section.)
If equipped with a thermostatically controlled radiator
shutter system, this system should be regulated in such a
way that the shutters are completely open by the time the
coolant reaches 93°C (200°F) to prevent excessive intake
manifold temperatures. Manually controlled systems are
not recommended.
If air-to-air aftercooling is used, the shutters must be
completely open by the time the intake manifold air
temperature reaches the maximum allowable temperature
out of the charge air cooler.
For more information, see your John Deere dealer.
DX,FUEL10 -19-20APR11-1/1
3-1-5
080913
PN=53
Maintenance—Machine
Alternative and Synthetic Lubricants
Conditions in certain geographical areas may require
lubricant recommendations different from those printed in
this manual.
Some John Deere brand coolants and lubricants may not
be available in your location.
The temperature limits and service intervals shown in
this manual apply to both conventional and synthetic
lubricants.
Re-refined base stock products may be used if the
finished lubricant meets the performance requirements.
Consult your John Deere dealer to obtain information and
recommendations.
Synthetic lubricants may be used if they meet the
performance requirements as shown in this manual.
104o F
John Deere Plus-50™ II oil is preferred.
30 o C
86 o F
20 o C
68 o F
10 o C
50 o F
0o C
32 o F
-10 o C
14 o F
-20 o C
-4 o F
-30 o C
-22 o F
-40 o C
-40 o F
John Deere Plus-50™ is also recommended.
Other oils may be used if they meet one or more of the
following:
• John Deere Torq-Gard™
• API Service Category CJ-4
• API Service Category CI-4 PLUS
• API Service Category CI-4
• ACEA Oil Sequence E9
• ACEA Oil Sequence E7
• ACEA Oil Sequence E6
• ACEA Oil Sequence E5
• ACEA Oil Sequence E4
Multi-viscosity diesel engine oils are preferred.
Diesel fuel quality and fuel sulfur content must comply
with all existing emissions regulations for the area in
which the engine operates.
TS1691 —UN—18JUL07
40 o C
SAE 10W-30
Use oil viscosity based on the expected air temperature
range during the period between oil changes.
SAE 15W-40
122o F
SAE 10W-40
50 o C
SAE 5W-30
Diesel Engine Oil
SAE 0W-40
DX,ALTER -19-11APR11-1/1
Oil Viscosities for Air Temperature Ranges
DO NOT use diesel fuel with sulfur content greater than
10 000 mg/kg (10 000 ppm).
Plus-50 is a trademark of Deere & Company
Torq-Gard is a trademark of Deere & Company
DX,ENOIL11 -19-11APR11-1/1
3-1-6
080913
PN=54
Maintenance—Machine
Diesel Engine Oil and Filter Service Intervals
The oil and filter service intervals in the following table
should be used as guidelines. Actual service intervals
also depend on operation and maintenance practices. It
is suggested to use oil analysis to determine the actual
useful life of the oil and to aid in selection of the proper
oil and filter service interval.
IMPORTANT: When using biodiesel blends greater
than B20, reduce the oil and filter service
interval by 50% or monitor engine oil based
on test results from Oilscan.
Oil and filter service intervals are based on a combination
of oil pan capacity, type of engine oil and filter used, and
sulfur content of the diesel fuel.
• John Deere Plus-50™ II and John Deere Plus-50
• “Other Oils” include John Deere Torq-Gard Supreme™,
Diesel fuel sulfur level will affect engine oil and filter
service intervals. Higher fuel sulfur levels reduce oil and
filter service intervals as shown in the table.
Use of lower specification oils in Tier 3 engines may result
in premature engine failure.
• Use of diesel fuel with sulfur content less than 0.10%
•
•
•
(1000 mg/kg) is strongly recommended.
Use of diesel fuel with sulfur content 0.10% (1000
mg/kg) to 0.50% (5000 mg/kg) may result in REDUCED
oil and filter change intervals as shown in the table.
BEFORE using diesel fuel with sulfur content greater
than 0.50% (5000 mg/kg), contact your John Deere
dealer.
DO NOT use diesel fuel with sulfur content greater than
1.00% (10 000 mg/kg).
Oil types in the table include:
API CJ-4, API CI-4 PLUS, API CI-4, ACEA E9, ACEA
E7, ACEA E6, ACEA E5, or ACEA E4 oils.
NOTE: The 500 hour extended oil and filter change interval
is only allowed if all the following conditions are met:
• Engine equipped with an extended drain
interval oil pan
• Use of diesel fuel with sulfur content less
than 0.50% (5000 mg/kg)
• Use of John Deere Plus-50™ II or John
Deere Plus-50 oil
• Use of an approved John Deere oil filter
U.S. Tier 3 and EU Stage III A - PowerTech Plus™
U.S. Tier 3 and EU Stage III A - PowerTech™
Oil Pan Size (L/kW)
Oil pan capacity
Greater than or
equal to 0.10
Fuel Sulfur
Greater than or
equal to 0.12
Greater than or
equal to 0.14
Oil Pan Size (L/kW)
Greater than or
equal to 0.22
Greater than or
equal to 0.10
Less than 0.10% (1000 mg/kg)
Greater than or
equal to 0.12
Greater than or
equal to 0.14
Less than 0.10% (1000 mg/kg)
Plus-50
375 hours
500 hours
500 hours
500 hours
375 hours
500 hours
500 hours
Other Oils
250 hours
250 hours
250 hours
250 hours
250 hours
250 hours
250 hours
Fuel Sulfur
0.10 - 0.20% (1000 - 2000 mg/kg)
0.10 - 0.20% (1000 - 2000 mg/kg)
Plus-50
300 hours
300 hours
500 hours
500 hours
300 hours
400 hours
500 hours
Other Oils
200 hours
200 hours
250 hours
250 hours
200 hours
200 hours
250 hours
Fuel Sulfur
0.20 - 0.50% (2000 - 5000 mg/kg)
0.20 - 0.50% (2000 - 5000 mg/kg)
Plus-50
250 hours
250 hours
300 hours
500 hours
275 hours
350 hours
500 hours
Other Oils
150 hours
150 hours
200 hours
250 hours
150 hours
175 hours
250 hours
Fuel Sulfur
0.50 - 1.00% (5000 - 10 000 mg/kg)
Plus-50
Contact John Deere Dealer (dealer refers to DTAC solutions)
187 hours
0.50 - 1.00% (5000 - 10 000 mg/kg)
250 hours
250 hours
Other Oils
Contact John Deere Dealer (dealer refers to DTAC solutions)
125 hours
125 hours
125 hours
The service interval of “Other Oils” may be extended only if oil analysis is performed to determine the actual service life, to a maximum not to
exceed that of Plus-50.
Plus-50 is a trademark of Deere & Company
Torq-Gard Supreme is a trademark of Deere & Company
PowerTech Plus is a trademark of Deere & Company
PowerTech is a trademark of Deere & Company
DX,ENOIL13 -19-03AUG09-1/1
3-1-7
080913
PN=55
2000 hour change interval:
122˚F
40˚C
104˚F
30˚C
86˚F
20˚C
68˚F
10˚C
50˚F
0˚C
32˚F
-10˚C
14˚F
-20˚C
-4˚F
-30˚C
-22˚F
-40˚C
-40˚F
• Super EX 46HN Hitachi excavator oil from John Deere
1000 hour change interval:
The following products can be used provided a complete
hydraulic system flush has been performed. Contact your
dealer for this procedure.
Biodegradable Hydraulic Oil:
TX1079198 —UN—24JUN10
The following oil is preferred:
50˚C
Premium AW32
Use oil viscosity based on the expected air temperature
range during the period between oil changes.
Premium AW 46
IMPORTANT: Avoid mixing different brands or types
of oils. Oil manufacturers engineer their oils to
meet certain specifications and performance
requirements. Mixing different oil types can
degrade lubricant and machine performance.
Super EX 46HN
Hydraulic Oil
Daphne Super Hydro A 32
Maintenance—Machine
Use only Exxon Mobil EAL Envirosyn 46H Synthetic
Esther Oil when a biodegradable oil is required. (Contact
your John Deere dealer for Registration and Routine Oil
Analysis to meet warranty requirements.)
DW90712,0000141 -19-27FEB12-1/1
Travel Gearbox Oil
Use oil viscosity based on the expected air temperature
range during the period between oil changes.
The following oils are preferred:
• John Deere GL-5 GEAR LUBRICANT
• John Deere EXTREME-GARD ™
TS1653 —UN—14MAR96
Other oils may be used if they meet API Service
Classification GL-5.
EXTREME-GARD is a trademark of Deere & Company.
MM61211,0000A5C -19-07DEC05-1/1
3-1-8
080913
PN=56
Maintenance—Machine
Grease
Use grease based on NLGI consistency numbers and the
expected air temperature range during the service interval.
John Deere HD Moly Grease is preferred.
Other greases may be used if they meet the following:
• NLGI Performance Classification GC-LB with 3–5%
molybdenum disulfide
TS1674 —UN—31OCT03
IMPORTANT: Some types of grease thickeners are not
compatible with others. Consult your grease
supplier before mixing different types of grease.
Greases for Air Temperature Ranges
DX,GREA4 -19-14APR11-1/1
3-1-9
080913
PN=57
Maintenance—Machine
Light Duty Diesel Engine Coolant (for diesel engines without wet sleeve cylinder liners)
• Protects the cooling system metals (cast iron, aluminum
The engine cooling system is filled to provide year-round
protection against corrosion and cylinder liner pitting, and
winter freeze protection to -37°C (-34°F). If protection at
lower temperatures is required, consult your John Deere
dealer for recommendations.
The coolant concentrate or prediluted coolant shall be of a
quality that is suitable for all-aluminum engines.
The following engine coolants are preferred:
Water Quality
• John Deere COOL-GARD™ II Premix
• John Deere COOL-GARD II PG Premix
Water quality is important to the performance of the
cooling system. Distilled, deionized, or demineralized
water is recommended for mixing with ethylene glycol
base engine coolant concentrate.
Use John DeereCOOL-GARD™ II PG Premix when a
non-toxic coolant formulation is required.
alloys, and copper alloys such as brass) from corrosion.
Coolant Drain Intervals
Additional Recommended Coolants
The following engine coolant is also recommended:
• John Deere COOL-GARD II Concentrate in a 40—60%
mixture of concentrate with quality water.
Drain and flush the cooling system and refill with fresh
coolant at the indicated interval, which varies with the
coolant used.
When John Deere COOL-GARD II is used, the drain
interval is six years or 6000 hours of operation.
Other Coolants
Other ethylene glycol or propylene glycol base
coolants may be used if they meet one of the following
specifications:
• ASTM D3306 prediluted (50%) coolant
• ASTM D3306 coolant concentrate in a 40—60% mixture
of concentrate with quality water
If these coolants are unavailable, use an engine coolant
concentrate or prediluted coolant with a minimum of the
following chemical and physical properties:
• Is formulated with a quality nitrite-free additive package.
When John Deere COOL-GARD II PG is used, the drain
interval is five years or 5000 hours of operation.
If a coolant other than COOL-GARD II or COOL-GARD
II PG is used, reduce the drain interval to two years or
2000 hours of operation.
IMPORTANT: Do not use cooling system sealing
additives or antifreeze that contains
sealing additives.
Do not mix ethylene glycol and propylene
glycol base coolants.
COOL-GARD is a trademark of Deere & Company
DX,COOL18 -19-20APR11-1/1
Drain Intervals for Diesel Engine Coolant
Drain and flush the cooling system and refill with fresh
coolant at the indicated interval, which varies with the
coolant used.
John Deere COOL-GARD™ II Premix, COOL-GARD
II PG Premix and COOL-GARD II Concentrate are
maintenance free coolants for up to six years or 6000
hours of operation, provided that the cooling system is
topped off using only John Deere COOL-GARD II Premix
or COOL-GARD II PG Premix.
Test the coolant condition annually with Coolant Test
Strips designed for use with John Deere COOL-GARD
II coolants. If the test strip chart indicates that additive
is required, add John Deere COOL-GARD II Coolant
Extender as directed.
If John Deere COOL-GARD™ II Premix, COOL-GARD II
PG Premix, or COOL-GARD II Concentrate is used, but
the coolant is not tested OR additives are not replenished
by adding John Deere COOL-GARD II Coolant Extender,
the drain interval is four years or 4000 hours of operation.
This drain interval only applies to COOL-GARD II coolants
that have been maintained within a 40—60% mixture of
concentrate with quality water.
If a coolant other than COOL-GARD II, or COOL-GARD
II PG is used, reduce the drain interval to two years or
2000 hours of operation.
COOL-GARD is a trademark of Deere & Company
DX,COOL11 -19-14APR11-1/1
3-1-10
080913
PN=58
Maintenance—Machine
John Deere COOL-GARD™ II Coolant Extender
Some coolant additives will gradually deplete during
engine operation. For John Deere COOL-GARD™ II
Premix, COOL-GARD II PG Premix, and COOL-GARD II
Concentrate, replenish coolant additives between drain
intervals by adding John Deere COOL-GARD II Coolant
Extender.
IMPORTANT: Do not add a supplemental coolant
additive when the cooling system is drained
and refilled with any of the following:
John Deere COOL-GARD II Coolant Extender should not
be added unless indicated by coolant testing.
The use of non-recommended supplemental coolant
additives may result in additive drop-out, gelation of the
coolant, or corrosion of cooling system components.
John Deere COOL-GARD II Coolant Extender is a
chemically matched additive system for use with all
John Deere COOL-GARD II coolants. John Deere
COOL-GARD II Coolant Extender is not intended for use
with nitrite-containing coolants.
• John Deere COOL-GARD II
• John Deere COOL-GARD II PG
Add the recommended concentration of John Deere
COOL-GARD II Coolant Extender. DO NOT add more
than the recommended amount.
COOL-GARD is a trademark of Deere & Company
DX,COOL16 -19-20APR11-1/1
Supplemental Coolant Additives
Some coolant additives will gradually deplete during
engine operation. For nitrite-containing coolants,
replenish coolant additives between drain intervals by
adding a supplemental coolant additive as determined
necessary by coolant testing.
John Deere Liquid Coolant Conditioner is recommended
as a supplemental coolant additive for nitrite-containing
coolants.
John Deere Liquid Coolant Conditioner is not designed
for use with John Deere COOL-GARD™ II Premix,
COOL-GARD II PG Premix, or COOL-GARD II
Concentrate.
• John Deere COOL-GARD II
• John Deere COOL-GARD II PG
If other coolants are used, consult the coolant supplier
and follow the manufacturer's recommendation for use of
supplemental coolant additives.
The use of non-recommended supplemental coolant
additives may result in additive drop-out and gelation of
the coolant.
Add the manufacturer's recommended concentration of
supplemental coolant additive. DO NOT add more than
the recommended amount.
IMPORTANT: Do not add a supplemental coolant
additive when the cooling system is drained
and refilled with any of the following:
COOL-GARD is a trademark of Deere & Company
DX,COOL4 -19-14APR11-1/1
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080913
PN=59
Maintenance—Machine
Operating in Warm Temperature Climates
John Deere engines are designed to operate using glycol
base engine coolants.
Always use a recommended glycol base engine coolant,
even when operating in geographical areas where freeze
protection is not required.
John Deere COOL-GARD™ II Premix is available in a
concentration of 50% ethylene glycol. However, there
are situations in warm temperature climates where a
coolant with lower glycol concentration (approximately
20% ethylene glycol) has been approved. In these cases,
the low glycol formulation has been modified to provide
the same level of corrosion inhibitor as John Deere
COOL-GARD II Premix (50/50).
IMPORTANT: Water may be used as coolant in
emergency situations only.
Foaming, hot surface aluminum and iron
corrosion, scaling, and cavitation will occur
when water is used as the coolant, even when
coolant conditioners are added.
Drain cooling system and refill with
recommended glycol base engine coolant
as soon as possible.
COOL-GARD is a trademark of Deere & Company
DX,COOL6 -19-03NOV08-1/1
3-1-12
080913
PN=60
Maintenance—Machine
Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™
II Coolant Extender
Engine coolants are a combination of three chemical
components: ethylene glycol (EG) or propylene glycol
(PG) antifreeze, inhibiting coolant additives, and quality
water.
Coolant Specifications
John Deere COOL-GARD™ II Premix either EG or
PG, are fully formulated coolants that contain all three
components in their correct concentrations. DO NOT
add an initial charge of John Deere COOL-GARD II
Coolant Extender to COOL-GARD II Premix. DO NOT
add any other supplemental coolant additive or water to
COOL-GARD II Premix.
John Deere COOL-GARD II Concentrate contains both
ethylene glycol and inhibiting coolant additives. Mix this
product with quality water, but DO NOT add an initial
charge of John Deere COOL-GARD II Coolant Extender
or any other supplemental coolant additive.
Replenish Coolant Additives
Some coolant additives will gradually deplete during
engine operation. Periodic replenishment of inhibitors
is required, even when John Deere COOL-GARD II
Premix or COOL-GARD II Concentrate is used. Follow
the recommendations in this manual for the use of John
Deere COOL-GARD II Coolant Extender.
Why use John Deere COOL-GARD II Coolant
Extender?
Operating without proper coolant additives will result in
increased corrosion, cylinder liner erosion and pitting, and
other damage to the engine and cooling system. A simple
mixture of ethylene glycol or propylene glycol and water
will not give adequate protection.
John Deere COOL-GARD II Coolant Extender is a
chemically matched additive system designed to fortify the
proprietary additives used in John Deere COOL-GARD II
Premix and COOL-GARD II Concentrate and to provide
optimum protection for up to six years or 6000 hours of
operation.
Avoid Automotive-type Coolants
Never use automotive-type coolants (such as those
meeting ASTM D3306). These coolants do not contain the
correct additives to protect heavy-duty diesel engines. Do
not treat an automotive engine coolant with supplemental
coolant additives because the high concentration of
additives can result in additive fallout.
Water Quality
Water quality is important to the performance of the
cooling system. Distilled, deionized, or demineralized
water is recommended for mixing with ethylene glycol
and propylene glycol base engine coolant concentrate.All
water used in the cooling system should meet the
following minimum specifications for quality:
Chlorides
<40 mg/L
Sulfates
<100 mg/L
Total dissolved solids
<340 mg/L
Total hardness
<170 mg/L
pH
5.5 to 9.0
Freeze Protection
The relative concentrations of glycol and water in the
engine coolant determine its freeze protection limit.
Ethylene Glycol
Freeze Protection Limit
40%
-24°C (-12°F)
50%
-37°C (-34°F)
60%
-52°C (-62°F)
Propylene Glycol
Freeze Protection Limit
40%
-21°C (-6°F)
50%
-33°C (-27°F)
60%
-49°C (-56°F)
DO NOT use a coolant-water mixture greater than 60%
ethylene glycol or 60% propylene glycol.
COOL-GARD is a trademark of Deere & Company
DX,COOL17 -19-20APR11-1/1
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080913
PN=61
Maintenance—Machine
Testing Diesel Engine Coolant
Maintaining adequate concentrations of glycol and
inhibiting additives in the coolant is critical to protect the
engine and cooling system against freezing, corrosion,
and cylinder liner erosion and pitting.
Test the coolant solution at intervals of 12 months or less
and whenever excessive coolant is lost through leaks or
overheating.
Coolant Test Strips
Add only the recommended concentration of John Deere
COOL-GARD II Coolant Extender. DO NOT add more
than the recommended amount.
When Using Nitrite-Containing Coolants
Compare the test strip results to the supplemental coolant
additive (SCA) chart to determine the amount of inhibiting
additives in your coolant and whether more John Deere
Liquid Coolant Conditioner should be added.
Coolant test strips are available from your John Deere
dealer. These test strips provide a simple, effective
method to check the freeze point and additive levels of
your engine coolant.
Add only the recommended concentration of John Deere
Liquid Coolant Conditioner. DO NOT add more than the
recommended amount.
When Using John Deere COOL-GARD II
Coolant Analysis
John Deere COOL-GARD II Premix™ , COOL-GARD
II PG Premix and COOL-GARD II Concentrate are
maintenance free coolants for up to six years or 6000
hours of operation, provided that the cooling system is
topped off using only John Deere COOL-GARD II Premix
or COOL-GARD II PG premix. Test the coolant condition
annually with coolant test strips designed for use with
John Deere COOL-GARD II coolants. If the test strip
chart indicates that additive is required, add John Deere
COOL-GARD II Coolant Extender as directed.
For a more thorough evaluation of your coolant, perform a
coolant analysis. The coolant analysis can provide critical
data such as freezing point, antifreeze level, pH, alkalinity,
nitrite content (cavitation control additive), molybdate
content (rust inhibitor additive), silicate content, corrosion
metals, and visual assessment.
Contact your John Deere dealer for more information on
coolant analysis.
COOL-GARD is a trademark of Deere & Company
DX,COOL9 -19-11APR11-1/1
3-1-14
080913
PN=62
Maintenance—Periodic Maintenance
Service Machine at Specified Intervals
Lubricate, make service checks, and make adjustments at
intervals shown on the periodic maintenance chart and on
the following pages.
Perform service on items at multiples of the original
requirement. For example, at 500 hours also service
those items (if applicable) listed under 250 hours, 100
hours, 50 hours, and 10 hours or daily.
TX14740,0001C9F -19-17JUL07-1/1
Check the Hour Meter Regularly
Check the hour meter (1) to determine when your machine
needs periodic maintenance.
Intervals on the periodic maintenance chart are for
operating in normal conditions. If you operate your
machine in difficult conditions, you should service it at
SHORTER INTERVALS.
T216999 —UN—07NOV05
1— Hour Meter
MM61211,0000985 -19-18APR06-1/1
Preparing Machine for Maintenance
1. Park machine on a level surface as shown.
2. Stop engine.
3. Move pilot control shutoff lever to locked (rearward)
position.
T121197 —UN—21APR99
Before performing maintenance procedures given in the
following sections and before leaving the operator’s seat,
position machine as shown below unless another position
is specified in the procedure.
TX14740,0001E83 -19-25JAN07-1/1
3-2-1
080913
PN=63
Maintenance—Periodic Maintenance
CAUTION: Prevent possible injury from
unexpected component movement. Always
keep access door in the locked position when
servicing the engine area.
1. Pull latch to unlock engine access door (1).
2. Raise door and lock stopper (3) securely into locking
arm (2).
3. To close, raise door slightly and push on locking arm
to release stopper. Lower door and latch securely.
3— Stopper
T204971 —UN—07DEC04
1— Engine Access Door
2— Locking Arm
T204970 —UN—07DEC04
Engine Access Door
OUO1032,0001580 -19-16NOV04-1/1
Maintenance Access Cover
1. Push button (1) to release maintenance access cover
(2) latch.
CAUTION: Prevent injury from unexpected
component movement. Always engage
rod (4) in bracket (6) when working in
maintenance compartment.
3. Remove one end of rod (4) from rod holder (5) and
insert into bracket (6).
4— Rod
5— Rod Holder
6— Bracket
T204973 —UN—29NOV04
1— Release Button
2— Maintenance Access Cover
3— Wire
T204972 —UN—29NOV04
2. Lift cover slowly. Wire (3) will act as a stop.
MM61211,0000986 -19-04NOV05-1/1
3-2-2
080913
PN=64
Maintenance—Periodic Maintenance
Tilting the Operator Station
IMPORTANT: Avoid machine damage. Do not use
another method of tilting the operator station.
T205418 —UN—09DEC04
Avoid damaging the tilt mechanism or
operator station. Raise and lower the
operator station slowly.
Tilting Operator Station
1. Park machine on level surface with pilot shut-off lever
in the locked position.
Tilting Position
2. Close cab door, and windows, if equipped.
3.
Move boom directly in front of operator station and
retract all cylinders.
MM61211,0000987 -19-04NOV05-1/3
4. Loosen panel cap screws (1) and raise panel (2).
Tighten screws to hold panel in place.
T205611 —UN—07DEC04
IMPORTANT: Avoid damaging operator station
platform. Do not remove operator station
platform cap screws (3).
5. Remove three operator station mounting cap screws
(4) from rear of operator station.
T205612 —UN—07DEC04
3— Operator Station Platform
Cap Screw (2 used)
4— Operator Station Mounting
Cap Screw (3 used)
Canopy Machines
T205613 —UN—07DEC04
1— Panel Cap Screw (2 used)
2— Panel
Cab Machines
Continued on next page
3-2-3
MM61211,0000987 -19-04NOV05-2/3
080913
PN=65
Maintenance—Periodic Maintenance
IMPORTANT: Avoid potential machine damage.
Avoid contact between operator station
and hoses, swing casting, or boom while
tilting the operator station.
T217001A —UN—07NOV05
6. Turn tilt screw (1) clockwise to raise operator station.
Stop rotating tilt screw when disk (2) is at tilt stop line
(4).
7. If access to the interior of the cab is required, open
cab door and ensure both door latches are engaged.
Lowering Operator Station
IMPORTANT: Prevent damage to the cab door.
Cab door must be closed before lowering
operator station.
1. Turn tilt screw counterclockwise slowly until operator
station is completely lowered. Do not over-tighten tilt
screw.
2. Install operator station mounting cap screws in rear of
operator station. Tighten to specification.
Specification
1— Tilt Screw
2— Disk
3— Tilt Stop Decal
4— Tilt Stop Line
3. Loosen panel cap screws and lower panel. Tighten
cap screws.
Operator Station Tilt Cap
Screws—Torque............................................................................90 N·m
66 lb-ft
MM61211,0000987 -19-04NOV05-3/3
Fuel Tank
CAUTION: Handle fuel carefully. DO NOT fill the
fuel tank when engine is running.
DO NOT smoke while you fill the fuel tank
or service the fuel system.
To avoid condensation, fill the fuel tank at the end of each
day’s operation.
Specification
Fuel Tank—Capacity...................................................................... 40.0 L
10.6 gal
MM61211,0000988 -19-07NOV05-1/1
Checking Washer Fluid Level
Check level in washer fluid reservoir (1).
T205077 —UN—29NOV04
1— Washer Fluid Reservoir
OUO1032,0001583 -19-16NOV04-1/1
3-2-4
080913
PN=66
Maintenance—Periodic Maintenance
Hydraulic Breaker and Crusher Attachments
IMPORTANT: Avoid mixing different brands or types
of oils. Oil manufacturers engineer their oils to
meet certain specifications and performance
requirements. Mixing different oil types can
degrade lubricant and machine performance.
This excavator is factory filled with 46HN
extended life zinc-free hydraulic oil. Avoid
servicing this excavator with products that do
not meet this specification. If oils have been
mixed or if alternate service oils are desired,
the complete hydraulic system needs to be
totally flushed by an authorized dealer.
Hydraulic breaker or crusher operation subjects the
machine’s hydraulic system to possible contamination
and accelerated deterioration. The hydraulic return
filter and hydraulic oil must be replaced more often to
prevent damage to hydraulic pumps and other hydraulic
components. Use of different attachments may shorten oil
change interval. Use this table for reference.
Bucket, Breaker, and Crusher Attachments
Attachment
Percentage of Operating Time
Hydraulic Return Filter
Change Interval
Hydraulic Oil Change Interval
Bucket
100%
500 hours
2000 hours
Breaker or Crusher
100%
250 hours
1000 hours
VD76477,00000C8 -19-18APR06-1/1
Fluid Analysis Program Test Kits and 3-Way
Coolant Test Kit
Engine, hydraulic, power train, and coolant samples
should be taken from each system on a periodic basis,
usually prior to a filter and/or fluid change interval. Certain
systems require more frequent sampling. Consult your
authorized John Deere dealer on a maintenance program
for your specific application. Your authorized John Deere
dealer has the sampling products and expertise to assist
you in lowering your overall operating costs through fluid
sampling.
TX1003513A —UN—20FEB06
Fluid Analysis Program Test Kits and the 3-Way Coolant
Test Kit are John Deere fluid sampling products to help you
monitor machine maintenance and system condition. The
objective of a fluid sampling program is to ensure machine
availability when you need it and to reduce repair costs by
identifying potential problems before they become critical.
Fluid Analysis Kits
AM40430,00002FE -19-19OCT11-1/1
3-2-5
080913
PN=67
Maintenance—Periodic Maintenance
Service Intervals
Model: 27D
PIN/Serial Number:
Hour Meter Reading:
SERVICE INTERVALS
Service your machine at intervals shown on this chart. Also, perform service on items at multiples of the original requirement. For example, at 500
hours also service those items (if applicable) listed under 250 hours, 100 hours, 50 hours and 10 hours or daily.
FLUID SAMPLING
Fluid samples should be taken from each system at its recommended change interval prior to actually draining the
fluid. Regular oil sampling will extend the operational life of your machine.
As Required
□ Drain fuel tank sump
□ Replace rubber crawler
□ Replace bucket
□ Clean cab floor
□ Check and replace seat belt
□ Add coolant extender as indicated by COOL-GARD™ II test strips
Every 10 Hours or Daily
□ Grease front end pin joints
□ Grease bucket and link pins
□ Check engine oil level
□ Check hydraulic oil level
□ Check hoses and lines for leaks or looseness
□ Check water separator
□ Drain water separator
□ Check seat belt
□ Check fuel hoses for leaks, cracks, etc.
□ Check coolant level
□ Check bucket teeth
□ Check track sag
□ Check bucket hook (if equipped)
□ Check air conditioner (if equipped)
After First 50 Hours
□ Check and adjust fan belt tension
□ Check tightening torque of bolts and nuts
Every 100 Hours
□ Grease front joint pins
□ Grease bucket and link pins
□ Check and adjust fan belt tension
Every 250 Hours
□ Grease swing bearing gear
□ Check hoses and lines for cracks and bends
□ Check gear oil level
□ Check fuel hoses for cracks and bends
□ Drain hydraulic tank sump
□ Clean air cleaner element
□ Replace hydraulic filter element
□ Take engine oil sample
□ Check tightening torque of bolts and nuts
Every 500 Hours
□ Grease front end pin joints
□ Replace fuel filter
□ Grease blade pins
□ Clean radiator core
□ Grease swing internal gear
□ Clean air conditioner recirculation filter
□ Grease control lever universal joint
□ Take diesel fuel sample
□ Change engine oil and replace filter
□ Take gear oil sample
□ Replace hydraulic filter element
□ Take engine coolant sample
□ Take hydraulic reservoir oil sample
Every 1000 Hours
□ Change transmission oil
□ Check starter and alternator
□ Replace pilot filter element
□ Check and adjust valve clearance
□ Check fuel injection nozzles
□ Measure engine compression pressure
□ Replace fuel and water separator
□ Check coolant
Every 2000 Hours
□ Change hydraulic oil; clean suction screen
□ Check injection timing
□ Check radiator cap
□ Drain, flush, and refill radiator coolant
Continued on next page
3-2-6
JH91824,000058F -19-06OCT09-1/2
080913
PN=68
Maintenance—Periodic Maintenance
For recommended oil type and oil viscosities based on
operating temperatures, see Maintenance-Machine.
(Section 3-1).
COOL-GARD is a trademark of Deere & Company
JH91824,000058F -19-06OCT09-2/2
3-2-7
080913
PN=69
Maintenance—Periodic Maintenance
Required Parts
REQUIRED PARTS
Ensure machine performance and availability; use only genuine John Deere parts. Verify part numbers are current and that any
associated parts are also on hand, i.e., filter O-rings.
Description
Part Number
Every 250
Hours
Every 500
Hours
Every 1000
Hours
Every 2000
Hours
Every 6000
Hours
Engine Oil Filter
M801002
1
1
1
1
Hydraulic System Return Oil Filter
AT308568
1
1
1
1
1
O-Ring for AT308568
4621929
1
1
1
1
1
Fuel Filter Element
MIU800645
1
1
1
1
Air Filter Primary
RG60690
1
1
1
1
Pilot Control Oil Filter
4294130
1
1
1
Engine Rocker Arm Cover Gasket
M811429
1
1
1
Fuel and Water Separator Element
M811032
1
1
1
Heating and Air Conditioning Filter
Screen (rear)
4641220
As Required
Heating and Air Conditioning Filter
Screen (front)
4641221
As Required
Heating and Air Conditioning Filter
Screen (top)
4641222
As Required
Hydraulic System Suction Oil Filter
4617513
PLUS-50 ™ Oil
TY6389*
7.2 L
(7.6 qt)
7.2 L
(7.6 qt)
7.2 L
(7.6 qt)
API GL-5 Gear Oil
TY6296*
0.6 L
(0.63 qt)
0.6 L
(0.63 qt)
0.6 L
(0.63 qt)
35 L
(9.2 gal)
35 L
(9.2 gal)
32 L
(8.5 gal)
32 L
(8.5 gal)
As Required
7.2 L
(7.6 qt)
Hitachi SUPER EX 46HN Hydraulic Oil
(S.N. —254999)
2908-050*
(S.N. 255000—)
2908-050*
32 L
(8.5 gal)
COOL-GARD™ II Pre-Mix
(S.N. —254999)
TY26575
5.2 L
(5.5 qt)
(S.N. 255000—)
TY26575
5.0 L
(5.3 qt)
Coolant Extender
TY26603
As Needed
Fluid Analysis Kits
□ Diesel Engine Oil
AT317904
1
1
1
1
□ Hydraulic Oil
AT303189
1
1
1
1
1
□ Travel Gearbox Oil
AT303189
2
2
2
2
□ DIESELSCAN
AT180344
1
1
1
1
COOLSCAN PLUS™ Kit
AT183016
1
1
1
1
COOL-GARD™ II Test Strips
TY26605
1
1
1
For recommended oil type and oil viscosities based on
operating temperatures, see Maintenance-Machine.
(Section 3-1.)
PLUS-50 is a trademark of Deere & Company
COOL-GARD is a trademark of Deere & Company
COOLSCAN PLUS is a trademark of Deere & Company
CC28724,000017D -19-06OCT09-1/1
3-2-8
080913
PN=70
Maintenance—As Required
Cleaning Air Cleaner Element
1. Loosen clamps (2) to remove cover (3).
2. Remove element (1).
T123610 —UN—17AUG99
3. Tap element with the palm of your hand, NOT ON A
HARD SURFACE.
CAUTION: Prevent possible injury from flying
chips if compressed air is more than 210 kPa
(2.1 bar) (30 psi). Reduce compressed air to less
than 210 kPa (2.1 bar) (30 psi) when using for
cleaning purposes. Clear area of bystanders,
guard against flying chips, and wear personal
protection equipment including eye protection.
4. If this does not remove dust, use compressed air
under 210 kPa (2.1 bar) (30 psi).
T205083 —UN—29NOV04
5. Direct air up and down from inside to outside. Be
careful not to make a break in the element.
6. Install element.
7. Install cover with dust unloader valve (4) pointing
down and tighten clamps.
8. Check air filter restriction indicator (5). If necessary,
replace element. See Replacing Air Cleaner Element.
(Section 3-7.)
1— Air Cleaner Element
2— Clamp (2 used)
3— Cover
4— Dust Unloader Valve
5— Air Filter Restriction
Indicator
MM61211,000098A -19-07NOV05-1/1
Cleaning Radiator Core and Oil Cooler
guard against flying chips, and wear personal
protection equipment including eye protection.
CAUTION: Prevent possible injury from flying
chips if compressed air is more than 210 kPa
(2.1 bar) (30 psi). Reduce compressed air to less
than 210 kPa (2.1 bar) (30 psi) when using for
cleaning purposes. Clear area of bystanders,
Clean the radiator core and oil cooler with compressed air
or water. Blow air straight through fins to avoid bending
them.
OUO1032,000159E -19-17NOV04-1/1
3-3-1
080913
PN=71
Maintenance—As Required
Check Coolant
CAUTION: Explosive release of fluids from
pressurized cooling system can cause
serious burns.
TS281 —UN—15APR13
Remove radiator filler cap (1) only when engine
is cold or when cool enough to touch with bare
hands. Slowly loosen cap to relieve pressure
before removing completely.
IMPORTANT: John Deere COOL-GARD™ II
Coolant Extender does not protect against
freezing. Coolant extender prevents rust,
scale, and liner cavitation.
T205085 —UN—01DEC04
NOTE: Check coolant every 1000 hours or 1 year,
or when replacing 1/3 or more of coolant. Add
coolant extender as indicated by John Deere
COOL-GARD™ II test strips.
1. Remove radiator filler cap and test coolant solution.
Use one of the following kits to check coolant.
• COOL-GARD II Test Strips
•
Coolant test strips provide an effective method to
check freeze point and additive levels of engine
coolant. See your authorized dealer for COOL-GARD
II test strips and follow instructions on kit.
COOLSCAN PLUS™
For a more thorough evaluation of coolant, perform
COOLSCAN PLUS analysis, where available.
See your authorized dealer for information about
COOLSCAN PLUS.
2. Add John Deere COOL-GARD II Coolant Extender
as necessary. Follow instructions on container for
amount.
1— Radiator Filler Cap
Specification
Cooling System—Capacity...................................................................................................... 5.5 L
5.59 qt
3. Install radiator filler cap.
COOL-GARD is a trademark of Deere & Company
COOLSCAN PLUS is a trademark of Deere & Company
JH91824,00005B2 -19-31AUG09-1/1
3-3-2
080913
PN=72
Maintenance—Every 10 Hours or Daily
Checking Engine Oil Level
T204975 —UN—29NOV04
IMPORTANT: Prevent engine damage. Do not
run engine when oil level is below MIN.
level on dipstick.
The most accurate oil level reading is obtained when the
engine is cold before starting the engine for the day’s
operation.
1. Make sure dipstick (1) is fully seated.
2. Remove dipstick to check oil level.
AFTER THE ENGINE HAS BEEN RUN: Allow the oil
to drain into the oil pan for 10 minutes before checking
the oil level. Ten minutes after shutdown the engine oil
level must be above the cross-hatch area.
3. If necessary, remove filler cap (2) to add oil. (See
Section 3-1.)
1— Dipstick
2— Filler Cap
T204976 —UN—29NOV04
BEFORE THE ENGINE IS STARTED: The engine is
full when oil level is between MIN. and MAX levels
on dipstick.
OUO1032,0001585 -19-08DEC05-1/1
Checking Hydraulic Oil Tank Level
IMPORTANT: Prevent damage to hydraulic system
components. Do not run engine without
oil in hydraulic tank.
T205418 —UN—09DEC04
Avoid mixing different brands or types of
oils. Oil manufacturers engineer their oils to
meet certain specifications and performance
requirements. Mixing different oil types can
degrade lubricant and machine performance.
This excavator is factory filled with 46HN
extended life zinc-free hydraulic oil. Avoid
servicing this excavator with products that do
not meet this specification. If oils have been
mixed or if alternate service oils are desired,
the complete hydraulic system needs to be
totally flushed by an authorized dealer.
1. Park machine on a level surface and position machine
with cylinders fully retracted.
Continued on next page
3-4-1
MM61211,000098B -19-06JAN09-1/3
080913
PN=73
Maintenance—Every 10 Hours or Daily
2. Stop engine.
3. Check oil level on hydraulic oil sight gauge (1) on
hydraulic tank. Oil must be between marks on window.
T204977 —UN—29NOV04
If necessary, add oil.
4. To add oil: Open maintenance access cover.
1— Hydraulic Oil Sight Gauge
Oil Sight Gauge
MM61211,000098B -19-06JAN09-2/3
CAUTION: Avoid injury. High-pressure release of
oil from pressurized system can cause serious
burns or penetrating injury. Relieve pressure
by SLOWLY loosening cap (2).
T204980 —UN—30NOV04
5. Slowly turn cap (2) counterclockwise a few degrees to
relieve pressure. Remove cap.
6. Add oil. See Hydraulic Oil. (See Section 3-1.)
7. Install filler cap.
2— Hydraulic Oil Filler Cap
Hydraulic Oil Filler Cap
MM61211,000098B -19-06JAN09-3/3
Draining Fuel Tank Sump
1. Open drain valve (1) for several seconds to drain
water and sediment into a container. Dispose of waste
properly.
2. Close drain valve.
1— Fuel Tank Drain Valve
T204985 —UN—30NOV04
NOTE: Fuel tank drain valve (1) is located under
machine directly below fuel tank.
OUO1032,0001587 -19-16NOV04-1/1
3-4-2
080913
PN=74
Maintenance—Every 10 Hours or Daily
Draining Water Separator
1. Open engine access door to access water separator
(2).
2. Open drain valve (3) for several seconds to drain
water and sediment into a container. If water is difficult
to drain, loosen air bleed plug (1).
TX1053012 —UN—12DEC08
3. Dispose of waste properly.
4. Close drain valve.
5. Close access door.
3— Drain Valve
Water Separator (S.N. —254999)
TX1052932 —UN—11DEC08
1— Air Bleed Plug
2— Water Separator
Water Separator (S.N. 255000— )
OUO1032,0001588 -19-11DEC08-1/1
3-4-3
080913
PN=75
Maintenance—Every 10 Hours or Daily
Checking Recovery Tank Coolant Level
With the engine cold, coolant level must be between the
FULL and LOW marks on the recovery tank (2).
T205085 —UN—01DEC04
If coolant is below the LOW mark, add coolant to the
recovery tank.
CAUTION: Prevent possible injury from hot
spraying water. DO NOT remove radiator
filler cap (1) unless engine is cool. Then turn
cap slowly to the stop. Release all pressure
before you remove cap.
Recovery Tank
IMPORTANT: Avoid mixing different brands or types
of coolant. Coolant manufacturers engineer
their coolants to meet certain specifications
and performance requirements. Mixing
different coolant types can degrade coolant
and machine performance.
1— Radiator Filler Cap
2— Recovery Tank
NOTE: If recovery tank is full and radiator is low, check
for leaks in radiator cap and hose connections
between radiator and coolant recovery tank.
If recovery tank is empty, check for leaks. Repair as
required. Add coolant to the radiator then the recovery
tank.
Coolant level must be at bottom of the radiator filler neck.
VD76477,00000BB -19-19JUL05-1/1
Checking Bucket Teeth
NOTE: Alternate buckets may use different tooth
assemblies.
Check bucket teeth for wear. Replace tooth if tooth wear
is below 65 mm (2.6 in.)
CAUTION: Guard against injury from flying pieces
of metal; wear goggles or safety glasses.
CED,TX14740,6421 -19-03JUL02-1/1
Checking Track Sag—Rubber Track
1. Rotate upperstructure so front of upperstructure is
over travel motors (180°).
T121880 —UN—18JUN99
2. Lower the bucket and blade to raise both tracks off
ground.
3. Raise pilot control shut-off lever to locked position.
CAUTION: Prevent possible injury from
unexpected machine movement. Place blocks
under machine frame to support machine
while measuring track sag.
4. Place blocks under machine frame to support machine.
7. Stop engine.
5. Lower pilot control shut-off lever to unlocked position.
6. Rotate track so track joint is positioned at the upper
center of the track.
Continued on next page
3-4-4
MM61211,0000A5D -19-07DEC05-1/2
080913
PN=76
Maintenance—Every 10 Hours or Daily
8. Measure distance (1) from bottom of center roller to
inner ridge of rubber track.
T121709 —UN—10JUN99
Specification
Track—Sag.............................................................................10—15 mm
0.4—0.6 in.
9. If not to specification, adjust track sag. See Adjusting
Track Sag.
10. Repeat check on other side of machine.
T217423 —UN—09DEC05
1— Track Sag Distance
Track Sag Distance
MM61211,0000A5D -19-07DEC05-2/2
3-4-5
080913
PN=77
Maintenance—Every 10 Hours or Daily
Checking Track Sag—Steel Track—If
Equipped
T204987 —UN—30NOV04
1. Rotate upperstructure 90° and lower bucket to raise
track off ground.
2. Keep the angle (1) between boom and arm 90—110°
and position the bucket’s round side on the ground.
CAUTION: Prevent possible injury from
unexpected machine movement. Place blocks
under machine frame to support machine
while measuring track sag.
3. Place blocks under machine frame to support machine.
4. Rotate track forward two full rotations and then in
reverse two full rotations.
T204988 —UN—30NOV04
5. Stop engine.
6. Measure distance (2) at middle track roller from bottom
of track frame to top surface of track shoe.
Specification
Track—Sag.........................................................................120—140 mm
4.7—5.5 in.
7. If not to specification, adjust track sag. See Adjusting
Track Sag.
8. Repeat check on other side of machine.
1— Boom-to-Arm Angle
2— Track Frame-to-Track Shoe
Distance
MM61211,000098C -19-07NOV05-1/1
Track Sag General Information
To maximize undercarriage life, keep track sag within
specification. Tracks may require adjustment several
times during a working day due to changing soil type and
moisture content.
Adjust tracks in the actual operating conditions.
TIGHT TRACK: Packing causes a tight track. If material
packs in the undercarriage, adjust tracks with the material
packed in the components.
While the track spring will recoil and the machine can
continue to operate with a tight track, continued operation
will result in excessive pin and bushing wear, sprocket
popping, tooth tip wear, and excessive loads on the entire
undercarriage and travel drive system.
Machine productivity and fuel consumption are also
adversely affected because increased horsepower is
needed to move the machine.
LOOSE TRACK: A loose track has more side to side
motion, increasing side wear on the links, rollers and front
idler. An excessively loose track will slap at high ground
speeds, resulting in high impact loads on the sprocket
teeth, bushings, and carrier rollers.
MM61211,0000A5E -19-07DEC05-1/1
3-4-6
080913
PN=78
Maintenance—Every 10 Hours or Daily
Adjusting Track Sag
T204989 —UN—30NOV04
IMPORTANT: Prevent possible damage to track
components. DO NOT use the grease fitting on
the track adjusting cylinder for lubrication. Use
this fitting ONLY for track adjustment.
To tighten track, connect a grease gun to grease fitting
(1) (located through access hole [4] in track frame). Add
grease until sag is within recommended limits.
T121713 —UN—10JUN99
CAUTION: Prevent possible serious injury from
high-pressure grease penetrating your skin.
Do not remove grease fitting (1) from valve (2).
If grease does not escape immediately from
the vent hole when check valve is loosened,
slowly drive machine in forward and reverse
direction until grease escapes. DO NOT
disassemble parts until you know the correct
procedure and have the correct tools. See
your authorized John Deere dealer.
If an accident occurs, see a doctor immediately.
Any oil injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this
type of injury may call Deere & Company
Medical Department in Moline, Illinois, or other
knowledgeable medical source.
To loosen, slowly turn valve (2) counterclockwise; grease
will escape through the bleed hole (3).
Steel Track Shown
1— Grease Fitting
2— Valve
3— Bleed Hole
4— Access Hole
When amount of track sag is satisfactory, turn valve
clockwise to tighten.
OUO1032,000158B -19-18JUL06-1/1
Seat Belt
Seat belt and mounting hardware must be inspected for
wear or damage before operating the machine. Replace
the belt or mounting hardware if worn or damaged.
Replace the complete seat belt assembly every 3 years
regardless of appearance.
TX,10,DH3548 -19-29APR08-1/1
3-4-7
080913
PN=79
Maintenance—First 50, Then Every 100 Hours
Lubricate Bucket and Link Pins
T205831 —UN—07DEC04
Lubricate bucket and link pins until grease escapes from
joints. (See Section 3-1.) Lubricate every 10 hours when
working in mud and water.
Right Side Shown - 10 Points
CED,TX14740,6379 -19-28FEB12-1/1
3-5-1
080913
PN=80
Maintenance—First 50, Then Every 100 Hours
One Point
T205004 —UN—30NOV04
One Point
T205003 —UN—30NOV04
T205002 —UN—30NOV04
Grease Front Joint Pins
One Point
T205009 —UN—30NOV04
Two Points
T205008 —UN—30NOV04
Two Points
T205007 —UN—30NOV04
T205006 —UN—30NOV04
One Point
One Point
Continued on next page
3-5-2
MM61211,000098D -19-07NOV05-1/2
080913
PN=81
Maintenance—First 50, Then Every 100 Hours
Add grease until grease escapes from joints. Grease
every 10 hours when working in mud and water. (See
Section 3-1.)
MM61211,000098D -19-07NOV05-2/2
Inspect Fan Belt, Check and Adjust Tension
1. Check belt regularly for wear. Replace if necessary.
Specification
Belt—Deflection............................................................. 7—9 mm at 98 N
0.27—0.35 in. at 22 lb-ft
3. If deflection is not within specifications, loosen cap
screws (4) for adjusting strap.
4. Move alternator (2) until tension is correct.
5. Tighten cap screws.
T205324 —UN—09DEC04
3— Fan Belt Deflection
4— Adjustment Cap Screw (3
used)
T205323 —UN—09DEC04
1— Fan Pulley
2— Alternator
T217426A —UN—09DEC05
2. Check belt tension with belt tension gauge at midway
between alternator (2) and fan pulley (1).
MM61211,000098E -19-07NOV05-1/1
3-5-3
080913
PN=82
Maintenance—Every 250 Hours
Grease Swing Bearing
T204996 —UN—30NOV04
CAUTION: Prevent possible injury from
unexpected machine movement if controls are
moved by another person. Lubricating swing
bearing gear and rotating the upperstructure
must be done by one person.
Each time you leave the operators station:
• Lower the bucket to the ground
• Stop the engine
• Raise the pilot control shut-off lever to
the locked position.
1. Park machine on a level surface.
2. Turn key switch to OFF. Remove key from switch.
3. Lubricate swing bearing with 2—3 shots of grease at
grease fitting. (See Section 3-1.)
5. Repeat steps 2—4 seven times. It is not necessary to
start the engine the last time.
NOTE: Grease the swing bearing gear at 500 hours.
4. Start engine. Raise bucket several inches off the
ground and rotate upperstructure 90 degrees (1/4 turn).
MM61211,0000A69 -19-08DEC05-1/1
Checking Travel Gearbox Oil Level
1. Park the machine on level ground rotating travel
gearbox until positioned as shown.
T121259 —UN—22APR99
2. Lower bucket and blade to the ground.
3. Run engine at slow idle speed without load for 5
minutes.
4. Turn key switch to OFF. Remove key from switch.
5. Pull pilot control shut-off lever to locked position.
CAUTION: High pressure release of oils from
pressurized system can cause serious burns.
Wait for travel gearbox oil to cool. Keep body
and face away from check plug. Gradually loosen
check plug to release air to relieve pressure.
6. After travel gearbox has cooled, slowly loosen fill plug
(1) to release air to relieve pressure.
1— Fill Plug
2— Check Plug
9. Install plugs.
10. Check second travel gearbox oil level.
7. Remove check plug (2). Oil must be to bottom of hole.
8. If necessary, add oil until oil flows out of oil level check
plug hole. (See Section 3-1.)
MM61211,0000A5F -19-18APR06-1/1
3-6-1
080913
PN=83
Maintenance—Every 250 Hours
Draining Hydraulic Oil Tank Sump
T205034 —UN—30NOV04
CAUTION: High-pressure release of oil from
pressurized system can cause serious
burns or penetrating injury. The hydraulic
tank is pressurized. Slowly loosen cap
to release pressure.
1. Slowly loosen cap (1) to release pressure.
1— Hydraulic Tank Cap
MM61211,000098F -19-18APR06-1/2
2. Loosen drain plug (2) for several seconds to drain
water and sediment into a container. Do not remove
plug completely. Dispose of waste properly.
3. Tighten drain plug.
T217005A —UN—07NOV05
2— Hydraulic Sump Drain Plug
MM61211,000098F -19-18APR06-2/2
Replacing Hydraulic Oil Tank Filter
1. Park machine on a level surface with arm cylinder fully
retracted and bucket cylinder fully extended. Lower
bucket and blade to ground.
Continued on next page
3-6-2
T205418 —UN—09DEC04
NOTE: Perform this service at the first 250 hours of
operation and then at 500 hour intervals thereafter.
VD76477,0000059 -19-09JAN09-1/2
080913
PN=84
Maintenance—Every 250 Hours
2. Stop engine.
CAUTION: High-pressure release of oil from
pressurized system can cause serious
burns or penetrating injury. The hydraulic
tank is pressurized. Slowly loosen cap
to release pressure.
3. Slowly loosen hydraulic oil tank cap to release
hydraulic pressure. Remove cap.
4. Hold down filter cover (2) against light spring load
when removing cap screws (1).
5. Remove O-ring (3), spring (4), valve (5), and filter
element (6).
T205001 —UN—30NOV04
NOTE: Remove element and inspect for metal particles
and debris in bottom of filter can. Excessive
amounts of brass and steel particles can indicate
a hydraulic pump, motor, or valve malfunction, or
a malfunction in process. Rubber-type material
can indicate a cylinder packing problem.
6. Discard element and O-ring.
7. Install new filter element, valve, and spring.
8. Fill new filter with oil. See Hydraulic Oil. (Section 3-1.)
9. Install cover and new O-ring.
10. Install cap screws.
Specification
Cap Screw—Torque......................................................................49 N·m
36 lb-ft
IMPORTANT: Avoid hydraulic pump damage.
Hydraulic system must be bled whenever the
hydraulic oil filter is changed.
1— Cap Screw (4 used)
2— Cover
3— O-Ring
4— Spring
5— Valve
6— Filter Element
11. Bleed hydraulic system. See Bleed Hydraulic System.
(Section 4-1.)
VD76477,0000059 -19-09JAN09-2/2
Take Engine Oil Sample
See your authorized dealer.
OUT4001,000039B -19-14MAR12-1/1
3-6-3
080913
PN=85
Maintenance—Every 500 Hours
Changing Engine Oil and Replacing Filter
See Changing Engine Oil and Replacing Filter Section 3-5.
DW90712,0000110 -19-26APR06-1/1
Lubricate Swing Bearing Gear
T205010 —UN—30NOV04
CAUTION: Prevent possible injury from
unexpected machine movement if controls are
moved by another person. Lubricating swing
bearing gear and rotating the upperstructure
must be done by one person.
Each time you leave the cab:
• Lower the bucket to the ground
• Stop the engine
• Pull the pilot control shutoff lever to
the locked position.
2. In order to apply grease evenly to the swing gear,
raise the bucket approximately 200 mm (8 in.) off the
ground, swing upperstructure four 90° intervals and
apply grease at each interval. Add grease as required.
(See Section 3-1.)
1. Apply grease to grease fitting.
IMPORTANT: If water or mud is found in swing
gear area, see Operating in Water and
Mud. (Section 2-2.)
OUO1032,0001593 -19-28FEB12-1/1
Lubricate Control Lever Universal Joint
1. Lift boot (1). Remove screws (2).
2. Remove bracket (3).
T205011 —UN—30NOV04
3. Lubricate points shown.
4. Install bracket and screws.
5. Install boot.
3— Bracket
T205012 —UN—30NOV04
1— Boot
2— Screw (2 used)
Four Points
OUO1032,0001594 -19-28FEB12-1/1
3-7-1
080913
PN=86
Maintenance—Every 500 Hours
Replacing Final Fuel Filter
1. Turn fuel shutoff valve (1) to OFF.
2. Remove fuel filter (2). Dispose of waste properly.
T205024 —UN—30NOV04
3. Clean mounting surface for fuel filter.
4. Add a small amount of fuel to new filter and install.
5. Turn fuel shutoff valve to ON.
6. Turn the key switch to ON for 10—15 seconds to
engage automatic bleeding. Do not start engine.
7. Start engine. Stop engine. Check for fuel leakage.
1— Fuel Shut-Off Valve
2— Final Fuel Filter
OUO1032,0001595 -19-25JAN07-1/1
Lubricate Blade Pins
T205163 —UN—09DEC04
Lubricate blade pins until grease escapes from joint. See
Grease. (Section 3-1.)
Four Points
OUO1032,0001596 -19-28FEB12-1/1
3-7-2
080913
PN=87
Maintenance—Every 500 Hours
Replacing Air Cleaner Element
1. Loosen clamps (2) to remove cover (3).
2. Remove element (1).
T123610 —UN—17AUG99
3. Install new element.
4. Install cover with dust unloader valve (4) pointing
down and tighten clamps.
5. Check air filter restriction indicator (5).
4— Dust Unloader Valve
5— Air Filter Restriction
Indicator
T205083 —UN—29NOV04
1— Air Cleaner Element
2— Clamp (2 used)
3— Cover
MM61211,0000991 -19-07NOV05-1/1
Replacing Hydraulic Oil Tank Filter
See Replacing Hydraulic Oil Tank Filter (Section 3-6.)
DW90712,0000104 -19-06OCT09-1/1
Take Fluid Samples
See your authorized dealer for taking the following fluid
samples:
• Coolant
• Diesel Fuel
• Travel Gear Oil
• Hydraulic Oil
JH91824,00005B3 -19-06OCT09-1/1
3-7-3
080913
PN=88
Maintenance—Every 1000 Hours
Changing Travel Gearbox Oil
1. Park the machine on level ground, rotating travel
gearbox until positioned as shown.
T121260 —UN—22APR99
2. Stop engine.
CAUTION: High-pressure release of oil from
pressurized system can cause serious burns.
Wait for travel gearbox oil to cool. Keep body
and face away from check plug. Gradually
loosen fill plug to release pressure.
3. After travel gearbox has cooled, slowly loosen fill plug
(1) to release pressure.
4. Remove drain plug (3). Allow oil to drain into a
container. Dispose of waste oil properly. Install plug.
Two Places
1— Fill Plug
2— Check Plug
3— Drain Plug
5. Remove oil fill plug.
6. Remove check plug (2).
8. Install plugs.
7. Add oil to fill plug hole until oil flows out of oil level
check plug hole. See Hydraulic Oil. (See Section 3-1.)
9. Repeat steps 4—8 for other travel gearbox.
Specification
Travel Gearbox—Oil
Capacity (each)................................................................................ 0.6 L
0.63 qt
MM61211,0000992 -19-06JAN09-1/1
3-8-1
080913
PN=89
Maintenance—Every 1000 Hours
Replacing Pilot System Oil Filter
1. Open maintenance access cover.
T205034 —UN—30NOV04
CAUTION: High-pressure release of oil from
pressurized system can cause serious
burns or penetrating injury. The hydraulic
tank is pressurized. Slowly loosen cap
to release pressure.
2. Slowly loosen hydraulic tank cap (1) to release
pressure.
NOTE: Pilot filter access panel (2) is under the
left rear of machine.
Hydraulic Tank Cap
3. Remove screws (3) from pilot filter access panel.
T205033 —UN—30NOV04
3— Screw (3 used)
T205032 —UN—30NOV04
1— Hydraulic Tank Cap
2— Pilot Filter Access Panel
Continued on next page
3-8-2
MM61211,0000993 -19-18APR06-1/2
080913
PN=90
Maintenance—Every 1000 Hours
4. Turn filter case (1) counterclockwise to remove from
filter head (4).
5. Pull down on filter element (2) while moving it back
and forth to remove.
T121925 —UN—22JUN99
6. Remove and discard O-ring (3).
7. Apply a thin film of clean oil to new O-ring and install
in filter head.
8. Install new filter element by moving it back and forth
while pushing it upward.
9. Install filter case.
10. Install hydraulic oil cap.
1— Filter Case
2— Filter Element
IMPORTANT: Avoid hydraulic pump damage.
Hydraulic system must be bled whenever
the pilot oil filter is changed.
3— O-Ring
4— Filter Head
12. Install pilot filter access cover.
11. Bleed hydraulic system. See Bleeding Hydraulic
System. (Section 4-1.)
MM61211,0000993 -19-18APR06-2/2
Checking and Adjusting Engine Valve Lash
(Clearance)
See your authorized dealer for inspection and repair.
CED,TX14740,6434 -19-10JUN99-1/1
Checking Starter and Alternator
See your authorized dealer for inspection and repair.
CED,TX14740,6412 -19-10MAY99-1/1
Check Coolant
See Check Coolant. (Section 3-3.)
OUT4001,0000365 -19-12APR11-1/1
3-8-3
080913
PN=91
Maintenance—Every 2000 Hours
Draining Cooling System
Drain and flush cooling system using commercial products.
T205087 —UN—01DEC04
1. Check coolant hoses for cracks and leaks. Replace if
necessary.
2. Tighten clamps.
3. Check radiator and oil cooler for dirt, grease, leaks,
and loose or broken mountings. Clean radiator and
oil cooler fins.
CAUTION: Prevent possible injury from hot
spraying water. DO NOT remove radiator
filler cap unless engine is cool. Then turn
cap slowly to the stop.
1— Radiator Cap
4. Slowly turn radiator cap (1) to release pressure.
Remove cap.
MM61211,0000994 -19-22DEC08-1/2
5. Turn radiator drain valve (1) counterclockwise to open
valve. Allow coolant to drain into a container. Dispose
of waste coolant properly.
6.
Close drain valves.
T205089 —UN—01DEC04
IMPORTANT: Avoid mixing different brands or types
of coolant. Coolant manufacturers engineer
their coolants to meet certain specifications
and performance requirements. Mixing
different coolant types can degrade coolant
and machine performance.
7. Fill with proper coolant. (See Section 3-1.)
Drain Valve
Specification
Cooling System (S.N.
—254999)—Capacity....................................................................... 5.2 L
5.5 qt
Cooling System (S.N.
255000— )—Capacity...................................................................... 5.0 L
5.3 qt
1— Radiator Drain Valve
MM61211,0000994 -19-22DEC08-2/2
3-9-1
080913
PN=92
Maintenance—Every 2000 Hours
Cooling System Fill and Deaeration
IMPORTANT: Use only permanent-type low silicate
ethylene glycol base antifreeze in coolant
solution. Other types of antifreeze may
damage cylinder seals.
1. Start engine. Run engine until coolant reaches a warm
temperature.
FREEZING TEMPERATURES: Fill with permanent-type,
low silicate, ethylene glycol antifreeze (without stop-leak
additive) and clean, soft water.
3. Check coolant level at recovery tank.
Fill
NOTE: The level of the coolant in the cooling system
MUST BE repeatedly checked after all drain and
refill procedures to insure that all air is out of the
system which allows the coolant level to stabilize.
Check coolant level only when the engine is cold.
2. Stop engine. Allow coolant to cool.
4. Repeat Steps 1—3 until recovery tank coolant level is
repeatedly at the same level (stabilized).
Fill radiator to the bottom of the radiator fill neck and fill
recovery tank to the FULL mark.
Deaeration
The cooling system requires several warm-up and cool
down cycles to deaerate. It will NOT deaerate during
normal operation. Only during warm-up and cool down
cycles will the system deaerate.
5. If necessary, fill recovery tank to FULL mark.
6. Install recovery tank and radiator caps.
CED,TX14740,6458 -19-26JUN99-1/1
Changing Hydraulic Tank Oil and Cleaning
Suction Screen
T205418 —UN—09DEC04
NOTE: Change original Hitachi factory fill hydraulic oil
after first 2000 hours. Change every 1000 hours if
using any of the other recommended hydraulic oils.
IMPORTANT: Prevent damage to hydraulic
system components. DO NOT run engine
without oil in the tank.
Avoid mixing different brands or types of
oils. Oil manufacturers engineer their oils to
meet certain specifications and performance
requirements. Mixing different oil types can
degrade lubricant and machine performance.
2. Stop engine.
This excavator is factory filled with 46HN
extended life zinc-free hydraulic oil. Avoid
servicing this excavator with products that do
not meet this specification. If oils have been
mixed or if alternate service oils are desired,
the complete hydraulic system needs to be
totally flushed by an authorized dealer.
3. Remove cover above hydraulic oil tank.
1. Park machine on surface with arm cylinder fully
retracted and bucket cylinder fully extended. Lower
bucket and blade to ground.
Continued on next page
3-9-2
MM61211,0000995 -19-22DEC08-1/5
080913
PN=93
Maintenance—Every 2000 Hours
T205034 —UN—30NOV04
CAUTION: High-pressure release of oil from
pressurized system can cause serious
burns or penetrating injury. The hydraulic
tank is pressurized. Slowly loosen cap
to release pressure.
4. Slowly loosen hydraulic tank cap (1) to release
pressure. Remove cap.
5. Drain oil using a suction pump.
1— Hydraulic Tank Cap
Hydraulic Tank Cap
MM61211,0000995 -19-22DEC08-2/5
6. Remove or loosen drain plug (2) on bottom of hydraulic
oil tank. Allow remaining oil to drain into a container.
Dispose of waste oil properly.
7. Tighten drain plug (S.N. 255000— ).
T217005A —UN—07NOV05
2— Drain Plug
TX1052954 —UN—11DEC08
Drain Plug (S.N. —254999)
Drain Plug (S.N. 255000— )
Continued on next page
3-9-3
MM61211,0000995 -19-22DEC08-3/5
080913
PN=94
Maintenance—Every 2000 Hours
8.
Remove cover (1) with O-ring.
9. Remove suction filter (4) with rod (3).
10. Clean inside of tank and suction filter.
11. Replace hydraulic oil tank filter. (See Section 3-7.)
12. Install suction filter with rod.
13. Install drain plug (S.N. —254999).
14. Install cover so rod is securely inserted into support
(2) on cover.
15. Secure cover with screws.
3— Rod
4— Suction Filter
T204999 —UN—29NOV04
1— Cover
2— Rod Support
Exploded View
MM61211,0000995 -19-22DEC08-4/5
16. Add oil until it is between marks on sight gauge (1).
(See Section 3-1.)
IMPORTANT: Avoid hydraulic pump damage.
Hydraulic system must be bled whenever
the hydraulic oil is changed.
T204977 —UN—29NOV04
Specification
Hydraulic Tank (S.N.
—254999)—Oil
Capacity............................................................................................ 35 L
9.2 gal.
Hydraulic Tank (S.N.
255000— )—Oil
Capacity............................................................................................ 32 L
8.5 gal.
1— Sight Gauge
17. Bleed hydraulic system. See Bleeding Hydraulic
System. (Section 4-1.)
MM61211,0000995 -19-22DEC08-5/5
3-9-4
080913
PN=95
Maintenance—Every 6000 Hours
Draining Cooling System
Drain and flush cooling system using commercial products.
T205087 —UN—01DEC04
1. Check coolant hoses for cracks and leaks. Replace if
necessary.
2. Tighten clamps.
3. Check radiator and oil cooler for dirt, grease, leaks,
and loose or broken mountings. Clean radiator and
oil cooler fins.
CAUTION: Prevent possible injury from hot
spraying water. DO NOT remove radiator
filler cap unless engine is cool. Then turn
cap slowly to the stop.
1— Radiator Filler Cap
4. Slowly turn radiator filler cap (1) to release pressure.
Remove cap.
CC28724,0000095 -19-31AUG09-1/2
5. Turn radiator drain valve (1) counterclockwise to open
valve. Allow coolant to drain into a container. Dispose
of waste coolant properly.
6.
Close drain valves.
John Deere COOL-GARD™ II Pre-Mix coolant
is recommended when adding new coolant
to cooling system. Follow directions on
container for correct mixture ratio.
7. Fill with proper coolant. See Light Duty Engine
Coolant. (Section 3-1.)
Specification
Cooling System (S.N.
—254999)—Capacity....................................................................... 5.2 L
5.5 qt
T205089 —UN—01DEC04
IMPORTANT: Avoid mixing different brands or types
of coolant. Coolant manufacturers engineer
their coolants to meet certain specifications
and performance requirements. Mixing
different coolant types can degrade coolant
and machine performance.
Drain Valve
1— Radiator Drain Valve
Cooling System (S.N.
255000— )—Capacity...................................................................... 5.0 L
5.3 qt
COOL-GARD is a trademark of Deere & Company
CC28724,0000095 -19-31AUG09-2/2
3-10-1
080913
PN=96
Maintenance—Every 6000 Hours
Cooling System Fill and Deaeration
IMPORTANT: John Deere COOL-GARD™ II Pre-Mix
coolant is recommended when adding new
coolant to cooling system.
Deaeration
Follow directions on container for correct
mixture ratio.
The cooling system requires several warm-up and cool
down cycles to deaerate. It will NOT deaerate during
normal operation. Only during warm-up and cool down
cycles will the system deaerate.
Use only permanent-type low silicate ethylene
glycol base antifreeze in coolant solution. Other
types of antifreeze may damage cylinder seals.
1. Start engine. Run engine until coolant reaches a warm
temperature.
John Deere COOL-GARD™ II Pre-Mix coolant
is recommended when adding new coolant
to cooling system. Follow directions on
container for correct mixture ratio.
FREEZING TEMPERATURES: Fill with permanent-type,
low silicate, ethylene glycol antifreeze (without stop-leak
additive) and clean, soft water. Add John Deere
COOL-GARD™ II Coolant Extender as required.
Fill
Fill radiator to the bottom of the radiator fill neck and fill
recovery tank to the FULL mark.
2. Stop engine. Allow coolant to cool.
3. Check coolant level at recovery tank.
4. Repeat steps 1—3 until recovery tank coolant level is
repeatedly at the same level (stabilized).
NOTE: The level of the coolant in the cooling system
MUST BE repeatedly checked after all drain and
refill procedures to ensure that all air is out of the
system which allows the coolant level to stabilize.
Check coolant level only when the engine is cold.
5. If necessary, fill recovery tank to FULL mark.
6. Install recovery tank and radiator caps.
COOL-GARD is a trademark of Deere & Company
CC28724,0000096 -19-31AUG09-1/1
3-10-2
080913
PN=97
Miscellaneous—Machine
Do Not Service or Adjust Injection Nozzles
or High Pressure Fuel Pump
If injection nozzles are not working correctly or are dirty,
the engine will not run normally. (See your authorized
dealer for service.)
Do not service an injection pump that is not operating
correctly. (See your authorized injection pump service
center.)
Changing the injection pump in any way not approved by
the manufacturer will end the warranty. (See your copy of
the John Deere warranty on this machine.)
TX,90,FF3116 -19-07SEP06-1/1
Do Not Service Control Valves, Cylinders,
Pumps, or Motors
If these parts need service, see your authorized dealer.
Special tools and information are needed to service
control valves, cylinders, pumps, or motors.
TX,90,FF3114 -19-03JAN07-1/1
Precautions for Alternator and Regulator
When batteries are connected, follow these rules:
1. Disconnect negative (-) battery cable when you work
on or near alternator or regulator.
5. Connect batteries or a booster battery in the correct
polarity (positive [+] to positive [+] and negative [-] to
negative [-]).
2. Be sure alternator wires are correctly connected
BEFORE you connect batteries.
6. Do not disconnect the batteries when engine is
running and alternator is charging.
3. Do not ground alternator output terminal.
7. Disconnect battery cables before you connect battery
charger to the batteries.
4. Do not disconnect or connect any alternator or
regulator wires while batteries are connected or while
alternator is operating.
T82,EXMA,I -19-18APR06-1/1
4-1-1
080913
PN=98
Miscellaneous—Machine
Handling, Checking, and Servicing Batteries
Carefully
TS204 —UN—15APR13
CAUTION: Battery gas can explode. Keep sparks
and flames away from batteries. Use a flashlight
to check battery electrolyte level.
Never check battery charge by placing
a metal object across the posts. Use a
voltmeter or hydrometer.
Always remove grounded (-) battery clamp
first and replace it last.
Exploding Battery Gas
Sulfuric acid in battery electrolyte is
poisonous. It is strong enough to burn skin,
eat holes in clothing, and cause blindness
if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when
electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help
neutralize the acid.
3. Flush your eyes with water for 15—30 minutes.
Get medical attention immediately.
If acid is swallowed:
TS203 —UN—23AUG88
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but
do not exceed 1.9 L (2 quarts).
3. Get medical attention immediately.
WARNING: Battery posts, terminals, and related
accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.
If electrolyte spills on the floor, use one of the following
mixtures to neutralize the acid: 0.5 kg (1 lb) baking soda
in 4 L (1 gal) water, or 0.47 L (1 pt) household ammonia in
4 L (1 gal) water.
Battery Electrolyte
IMPORTANT: Do not overfill the battery cells.
Check the specific gravity of electrolyte in each battery cell.
Continued on next page
4-1-2
TX03679,0001788 -19-05MAR13-1/2
080913
PN=99
Miscellaneous—Machine
See your authorized dealer for JT05460
SERVICEGARD™ battery and coolant tester. Follow
directions included with the tester.
T85402 —UN—10NOV88
A fully charged battery will have a corrected specific
gravity reading of 1.260. If the reading is below 1.200,
charge the battery.
Battery and Coolant Tester
SERVICEGARD is a trademark of Deere & Company
TX03679,0001788 -19-05MAR13-2/2
Using Booster Batteries—12-Volt System
Before boost starting, machine must be properly shut
down to prevent unexpected machine movement when
engine starts.
TS204 —UN—15APR13
CAUTION: Prevent possible injury from exploding
battery. An explosive gas is produced while
battery is in use or being charged. Keep flames
or sparks away from the battery area. Make sure
the battery is charged in a well-ventilated area.
IMPORTANT: The machine electrical system is
a 12-volt negative (-) ground. Use only
12-volt booster batteries.
T204924 —UN—07DEC04
1. Connect one end of the positive cable to the positive
terminal of the machine battery and connect the other
end to the positive terminal of the booster batteries.
2. Connect one end of the negative cable to the negative
terminal of the booster batteries. Connect the other
end of the negative cable to the machine ground (1)
as far away from the machine battery as possible.
3. Start engine.
4. Immediately after starting engine disconnect end of
the negative cable from the machine. Then disconnect
the other end of the negative cable from the negative
terminal of the booster batteries.
1— Machine Ground
5. Disconnect positive cable from booster batteries and
machine battery.
MM61211,000097E -19-13DEC05-1/1
4-1-3
080913
PN=100
Miscellaneous—Machine
Using Battery Charger
TS204 —UN—15APR13
CAUTION: Prevent possible injury from exploding
battery. Do not charge a battery if the battery
is frozen or it may explode. Warm battery to
16°C (60°F) before charging.
IMPORTANT: Disconnect battery ground before you
charge batteries in the machine to prevent
damage to electrical components.
DO NOT use battery charger as a booster
if a battery has a 1.150 specific gravity
reading or lower. Turn off charger before
connecting or disconnecting it.
A battery charger may be used as a booster to start engine.
T82,EXMA,G -19-03AUG92-1/1
Replacing the Battery
Your machine has one 12-volt battery with negative (-)
ground. Battery must meet or exceeds the specifications
below.
Specification
Battery—Cold Cranking
Amps At -18°C (0°F)................................................................. 350 amps
Replace the failed battery with one of the same type. For
example, replace a failed maintenance-free battery with a
new maintenance-free battery. Different types of batteries
may have different rates of charge. This difference could
overload the battery and cause it to fail.
MM61211,0000A6A -19-08DEC05-1/1
Welding On Machine
IMPORTANT: Disconnect battery ground strap
to prevent voltage spikes through
alternator or monitor.
Do not weld within 12 inches of electronic
components. Remove electronic components
if necessary.
Disable electrical power before welding.
Disconnect positive battery cable. Separate
harness connectors to engine and vehicle
microprocessors.
Connect welder ground clamp close to
each weld area so electrical current does
not arc inside any bearings.
OUO1032,00015C0 -19-08DEC04-1/1
4-1-4
080913
PN=101
Miscellaneous—Machine
Bleed Hydraulic System
T205418 —UN—09DEC04
IMPORTANT: Avoid hydraulic pump damage. Perform
the hydraulic system bleeding procedure every
time you change the hydraulic filter, pilot system
oil filter, or change hydraulic tank oil.
Do not operate any hydraulic function, including
unlocking pilot control shutoff lever, until you
complete steps 1—5 in this procedure.
1. Turn engine speed control knob to slow idle position.
2. Start engine. Run for 5—10 seconds to ensure oil flow
to hydraulic pump. Stop engine.
3. Check the hydraulic oil level at the sight gauge. Add
hydraulic oil if necessary. (See Section 3-1.)
4. Start the engine again. Confirm oil level is above
minimum point in hydraulic oil sight gauge. Run
engine for approximately one minute to circulate oil
through the system.
5. Stop engine and check hydraulic oil level. Add more
oil if necessary.
6. Start engine again. Operate each cylinder and swing
motor repeatedly for 10—15 minutes to purge air from
hydraulic system.
7. Park machine on a level surface and position machine
with cylinders fully retracted.
8. Stop engine. Check hydraulic oil level. Add oil if
necessary.
OUO1032,0001599 -19-18APR06-1/1
Clean Machine Regularly
Remove any grease, oil, fuel, or debris build-up to avoid
possible injury or machine damage.
High pressure washing (greater than 1379 kPa (13.8
bar) (200 psi) can damage freshly painted finishes. Paint
should be allowed to air dry for 30 days minimum after
receipt of machine before cleaning with high pressure. Use
low pressure wash operations until 30 days have elapsed.
T6642EJ —UN—18OCT88
IMPORTANT: Directing pressurized water at
electronic/electrical components or connectors,
bearings and hydraulic seals, fuel injection
pumps or other sensitive parts and components
may cause product malfunctions. Reduce
pressure and spray at a 45 to 90 degree angle.
Clean Machine Regularly
Do not spray oil cooler fins at an angle. Fins may bend.
TX03679,00017E0 -19-05MAR13-1/1
12-Volt Auxiliary Power Outlet
A 12-volt auxiliary power outlet (1) is provided for service
and maintenance.
T205080 —UN—10DEC04
1— 12-Volt Auxiliary Power
Outlet
OUO1032,000159A -19-16NOV04-1/1
4-1-5
080913
PN=102
Miscellaneous—Machine
Connecting and Disconnecting Auxiliary
Lines
3. Switch the flow selector valve to the hammer mode.
(Left side of machine.)
NOTE: The right and left side is determined while the
operator is sitting in the seat facing forward looking at the boom and arm.
4. Disconnect the LEFT side hydraulic quick coupler.
This procedure will reduce amount of effort to make the
connection and disconnection of auxiliary lines.
6. Change the attachment. (Once the attachment is in
place-shut the machine off.)
1. Move the bucket clamp (thumb) to the storage position
(up) with 1 inch of cylinder rod exposed.
7. Connect the RIGHT side hydraulic coupler.
NOTE: If the rod is completely bottomed out this
procedure will not work.
9. Switch the flow selector valve, if necessary for the
particular type of attachment.
2. Turn the machine off.
10. Operate the machine.
5. Disconnect the RIGHT side hydraulic quick coupler.
8. Connect the LEFT side hydraulic coupler.
DW90712,0000102 -19-30JAN07-1/1
4-1-6
080913
PN=103
Miscellaneous—Machine
Replacing Fuses
The fuse panel (1) is located under the seat. Lower cover
to access.
T205082 —UN—01DEC04
IMPORTANT: Install fuse with correct amperage
rating to prevent electrical system damage
from overload.
Fuse (Blade-Type) Color Codes
Pink
5
Tan
7-1/2
Brown
10
Red
15
Light Blue
20
Yellow
25
Natural (white)
30
Light Green
1— F1—25 Amp—Horn, Fuel
Shut-Off Pull-In Coil
2— F2—5 Amp—Monitor,
A/C Controller (if
equipped), Radio (if
equipped)—Unswitched
3— F3—5 Amp—Pilot Shut-Off
Switch, Safety Start
4— F4—10 Amp—Auxiliary
Power Outlet
5— F5—20 Amp—Work Lights
6— F6—10 Amp—Wiper Motor
(if equipped), Washer
Switch (if equipped), and
Dome Light (if equipped)
12
1
5A
7— F7—25 Amp—Radio (if
equipped), A/C Controller
(if equipped), A/C Torque
Control Relay, Blower
Motor (if equipped)
8— F8—20 Amp—Travel Speed
Selector Switch, Travel
Alarm Controller, Travel
Alarm
9— F9—10 Amp—Monitor
Power Supply, Monitor
Alarm, Starter Interlock
Relay, Alternator Excite,
Fuel Shut-Off Solenoid
Hold-In Coil, Fuel Pump,
Travel Alarm
10— F10—5 Amp—Safety Start
Relay
11— F11—65 Amp—Main
Power Fuse
12— F12—5 Amp—Glow Plug
Power Fuse (S.N. 225112—
)
25A
5A
5A
10A
20A
10A
25A
20A
10A
5A
2
3
4
5
6
7
8
9
10
TX1032415 —UN—17JAN08
Violet
4
T205683A —UN—03DEC04
Black
3
5A
Color
1
25A 20A 10A
Amperage Rating
Main Power Fuse
SJ25320,000071A -19-18JAN08-1/1
4-1-7
080913
PN=104
Miscellaneous—Machine
Cleaning Heating and Air Conditioning Filter
Screens—If Equipped
2. Remove floor panel cap screws (2).
3. Remove floor panel assembly.
4. Remove three filter screens (3). Wipe off or rinse with
warm water.
5. Install filter screens.
6. Install floor panel assembly.
T205901A —UN—09DEC04
1. Remove floor mat (1).
7. Install floor panel cap screws.
8. Install floor mat.
T217013A —UN—08NOV05
3— Air Conditioning Filter
Screen (3 used)
T217012A —UN—08NOV05
1— Floor Mat
2— Floor Panel Cap Screw (3
used)
MM61211,0000998 -19-08NOV05-1/1
4-1-8
080913
PN=105
Miscellaneous—Machine
Installing Bucket With Quick Coupler
1. Position bucket and machine on a flat level surface.
2. Slowly lower boom and maneuver arm to insert arm
pivot pin (1) into open end of bucket ears (2).
3. Extend bucket cylinder (3) until the square pin boss (4)
rests on the flat surface of bucket ears (5).
T123697B —UN—19AUG99
4— Square Pin Boss
5— Bucket Ears
Machine Shown with Optional Thumb Attachment
T123698B —UN—19AUG99
1— Arm Pivot Pin
2— Bucket Ears
3— Bucket Cylinder
Continued on next page
4-1-9
OUO1032,00015A6 -19-19NOV04-1/2
080913
PN=106
Miscellaneous—Machine
4.
Install bucket or attachment and wedge bar (1). Two
lynch pins (2) are installed on rear of mechanical quick
coupler.
5. Tighten cap screw (3) to specification.
1— Wedge Bar
2— Lynch Pins
T130378C —UN—11JUL00
Specification
Cap Screw—Torque....................................................................135 N·m
100 lb-ft
3— Cap Screw
OUO1032,00015A6 -19-19NOV04-2/2
Checking Track Shoe Hardware
Tracks shoes should be checked periodically for loose
or missing cap screws and nuts. For shoes with missing
or loose cap screws and nuts, remove shoes and clean
the mating surface of shoes and links before tightening
cap screws and nuts. The cap screws should be replaced
because they have been stretched to yield previously.
Operating a machine with loose shoes can cause the cap
screws and holes in the shoes and links to wear making
it difficult to keep the shoes tight. Loose shoes can also
cause hardware failure and loss of shoes.
1. Clean the mating surface of shoe and links. Install
shoes.
2. Apply a light coating of oil to cap screw threads before
installing.
3. Install nuts with the rounded corners against milled
surface of link and chamfered side is away from link.
Check that nuts are square with the milled surface of
link and there is full contact between nut and milled
surface. As necessary, hold the nut so it does not turn.
4. Starting at any cap screw, tighten all cap screws in
sequence to the torque specification, then 1/2 turn
(180°) more.
TX14740,0001CFC -19-23JAN02-1/1
Rubber Track Care
CAUTION: Prevent possible injury from
unexpected machine movement. A machine with
rubber track is less stable than a machine with
steel shoes, as the edge of the rubber track
may bend when bucket is loaded, especially
when digging over the side.
When you drive the machine:
• Keep the rubber track free of oil, gasoline, etc.
•
•
Avoid
traveling on oil to reduce the chance of slipping.
If machine is parked or stored for more than 90 days,
park in an area out of direct sunlight.
When transporting a machine with rubber tracks, always
fasten the right and left track frames securely to the
trailer. Do not allow tie down chains to come into direct
contact with rubber track pads.
• Do not operate on sharp, rocky, uneven surfaces.
NOTE: The rubber track has a thin rubber film on its
inner surface when it is new. It is normal for the
film to come off when track rubs against rollers.
TX,55,DH5376 -19-25JAN07-1/1
4-1-10
080913
PN=107
Miscellaneous—Machine
Removing and Installing Rubber Track
2. Lower the bucket and blade to raise both tracks off
ground.
CAUTION: Prevent possible injury from
unexpected machine movement. Place blocks
under machine frame to support machine
while measuring track sag.
T204990 —UN—30NOV04
1. Rotate upperstructure so front of upperstructure is
over travel motors (180°).
3. Place blocks under machine frame to support machine.
MM61211,0000A60 -19-07DEC05-1/3
4. To loosen track, slowly turn valve (2) counterclockwise.
Grease will escape through the bleed hole (3).
CAUTION: Prevent potential injury from front
idler. This procedure will require additional help.
Do not stand in front of idler during removal of
track. Front idler may come off unexpectedly.
T204989 —UN—30NOV04
CAUTION: Prevent possible injury from
high-pressure grease. DO NOT remove grease
fitting (1) from valve (2).
6. Install the rubber track on the sprocket first. Position
the other end of the rubber track on the front idler.
7. While rotating the sprocket in reverse, push on the
rubber track to force it on the idler.
1— Grease Fitting
2— Valve
3— Bleed Hole
4— Steel Pipe
T204991 —UN—30NOV04
5. Insert two or three steel pipes (4) into gaps among
lower rollers, track frame, and rubber track. Rotate
track slowly in reverse to lift track off idler. Pry track
off idler.
MM61211,0000A60 -19-07DEC05-2/3
8. Insert a steel pipe (4) into gaps among lower rollers,
track frame, and rubber track and rotate slowly in
reverse to force the rubber track onto the idler.
10. Adjust track sag. See Adjusting Track Sag. (Section
3-4.)
11. Lower the machine to the ground.
4— Steel Pipe
T204992 —UN—30NOV04
9. Check that the rubber track is correctly engaged with
the sprocket and idler.
MM61211,0000A60 -19-07DEC05-3/3
4-1-11
080913
PN=108
Miscellaneous—Machine
Converting the Track
disassemble the track adjuster before converting
the track. See your authorized dealer.
The rubber track uses a different track adjuster than that
used for the steel track.
Change the track adjuster whenever converting the track.
See your authorized dealer for correct track adjuster.
CAUTION: Prevent possible injury from
high-pressure grease. DO NOT attempt to
CED,TX14740,6459 -19-18APR06-1/1
Unified Inch Bolt and Screw Torque Values
TS1671 —UN—01MAY03
Bolt or Screw
Size
1/4
5/16
3/8
7/16
SAE Grade 2a
SAE Grade 1
Lubricatedb
Dryc
Lubricatedb
SAE Grade 5, 5.1 or 5.2
Dryc
Lubricatedb
Dryc
SAE Grade 8 or 8.2
Lubricatedb
Dryc
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
3.7
33
4.7
42
6
53
7.5
66
9.5
84
12
106
13.5
120
17
150
N·m
lb.-ft.
N·m
lb.-ft.
28
20.5
35
26
7.7
13.5
68
120
22
194
N·m
lb.-ft.
9.8
86
12
106
15.5
137
17.5
155
22
194
27
240
N·m
lb.-ft.
N·m
lb.-ft.
N·m
lb.-ft.
28
20.5
35
26
44
32.5
lb.-in.
19.5
172
25
221
N·m
lb.-ft.
N·m
lb.-ft.
35
26
44
32.5
49
36
63
46
56
41
70
52
80
59
100
74
1/2
34
25
42
31
53
39
67
49
85
63
110
80
120
88
155
115
9/16
48
35.5
60
45
76
56
95
70
125
92
155
115
175
130
220
165
5/8
67
49
85
63
105
77
135
100
170
125
215
160
240
175
305
225
3/4
120
88
150
110
190
140
240
175
300
220
380
280
425
315
540
400
7/8
190
140
240
175
190
140
240
175
490
360
615
455
690
510
870
640
1
285
210
360
265
285
210
360
265
730
540
920
680
1030
760
1300
960
1-1/8
400
300
510
375
400
300
510
375
910
670
1150
850
1450
1075
1850
1350
1-1/4
570
420
725
535
570
420
725
535
1280
945
1630
1200
2050
1500
2600
1920
1-3/8
750
550
950
700
750
550
950
700
1700
1250
2140
1580
2700
2000
3400
2500
1-1/2
990
730
1250
930
990
730
1250
930
2250
1650
2850
2100
3600
2650
4550
3350
Torque values listed are for general use only, based on the strength of the bolt
or screw. DO NOT use these values if a different torque value or tightening
procedure is given for a specific application. For plastic insert or crimped steel
type lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the
tightening instructions for the specific application. Shear bolts are designed to fail
under predetermined loads. Always replace shear bolts with identical grade.
Replace fasteners with the same or higher grade. If higher
grade fasteners are used, tighten these to the strength of the
original. Make sure fastener threads are clean and that you
properly start thread engagement. When possible, lubricate
plain or zinc plated fasteners other than lock nuts, wheel bolts
or wheel nuts, unless different instructions are given for the
specific application.
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6
in. (152 mm) long, and for all other types of bolts and screws of any length.
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in.
and larger fasteners with JDM F13C, F13F or F13J zinc flake coating.
c
“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B, F13E or F13H zinc flake coating.
b
DX,TORQ1 -19-12JAN11-1/1
4-1-12
080913
PN=109
Miscellaneous—Machine
Metric Bolt and Screw Torque Values
TS1670 —UN—01MAY03
Bolt or Screw
Size
M6
M8
M10
4.8
8.8
9.8
10.9
12.9
12.9
4.8
8.8
9.8
10.9
12.9
12.9
Class 4.8
Lubricateda
Class 8.8 or 9.8
Dryb
Lubricateda
Class 10.9
Dryb
Lubricateda
Class 12.9
Dryb
Lubricateda
Dryb
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
4.7
42
6
53
8.9
79
11.3
100
13
115
16.5
146
15.5
137
19.5
172
N·m
lb.-ft.
N·m
lb.-ft.
N·m
lb.-ft.
N·m
lb.-ft.
32
23.5
40
29.5
37
27.5
47
35
63
46
80
59
75
55
95
70
11.5
102
14.5
128
22
194
27.5
243
N·m
lb.-ft.
N·m
lb.-ft.
N·m
lb.-ft.
29
21
43
32
55
40
lb.-in.
23
204
N·m
lb.-ft.
M12
40
29.5
50
37
75
55
95
70
110
80
140
105
130
95
165
120
M14
63
46
80
59
120
88
150
110
175
130
220
165
205
150
260
190
M16
100
74
125
92
190
140
240
175
275
200
350
255
320
235
400
300
M18
135
100
170
125
265
195
330
245
375
275
475
350
440
325
560
410
M20
190
140
245
180
375
275
475
350
530
390
675
500
625
460
790
580
M22
265
195
330
245
510
375
650
480
725
535
920
680
850
625
1080
800
M24
330
245
425
315
650
480
820
600
920
680
1150
850
1080
800
1350
1000
M27
490
360
625
460
950
700
1200
885
1350
1000
1700
1250
1580
1160
2000
1475
M30
660
490
850
625
1290
950
1630
1200
1850
1350
2300
1700
2140
1580
2700
2000
M33
900
665
1150
850
1750
1300
2200
1625
2500
1850
3150
2325
2900
2150
3700
2730
M36
1150
850
1450
1075
2250
1650
2850
2100
3200
2350
4050
3000
3750
2770
4750
3500
Torque values listed are for general use only, based on the strength of
the bolt or screw. DO NOT use these values if a different torque value or
tightening procedure is given for a specific application. For stainless steel
fasteners or for nuts on U-bolts, see the tightening instructions for the
specific application. Tighten plastic insert or crimped steel type lock nuts
by turning the nut to the dry torque shown in the chart, unless different
instructions are given for the specific application.
Shear bolts are designed to fail under predetermined loads. Always
replace shear bolts with identical property class. Replace fasteners with
the same or higher property class. If higher property class fasteners are
used, tighten these to the strength of the original. Make sure fastener
threads are clean and that you properly start thread engagement. When
possible, lubricate plain or zinc plated fasteners other than lock nuts,
wheel bolts or wheel nuts, unless different instructions are given for the
specific application.
a
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20
and larger fasteners with JDM F13C, F13F or F13J zinc flake coating.
b
“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B, F13E or F13H zinc flake coating.
DX,TORQ2 -19-12JAN11-1/1
4-1-13
080913
PN=110
Miscellaneous—Operational Checkout
Operational Checkout
Use this procedure to check all systems and functions on
the machine. It is designed so you can make a quick check
of machine operation while doing a walk around inspection
and performing specific checks from the operators seat.
Should you experience a problem with your machine, you
will find helpful diagnostic information in this checkout that
will pinpoint the cause. This information may allow you to
perform a simple adjustment yourself which will reduce
the down time of your machine. Use the table of contents
to help find adjustment procedures.
The information you provide after completing the
operational checkout will allow you or your authorized
dealer to pinpoint a specific test or repair needed to
restore the machine to design specifications.
A location will be required which is level and has adequate
space to complete the checks. No tools or equipment are
needed to perform the checkout.
Complete the necessary visual checks (oil levels, oil
condition, external leaks, loose hardware, linkage, wiring,
etc.) prior to doing the checkout. The machine must be at
operating temperature for many of the checks.
Start at the top of the left column and read completely down
column before performing check. Follow this sequence
from left to right. In the far right column, if no problem
is found, you will be instructed to go to next check. If a
problem is indicated, you will be referred to either a section
in this manual or to your authorized dealer for repair.
MM61211,0000999 -19-12SEP12-1/24
Operator Station Checks—Key Switch ON, Engine OFF
Continued on next page
4-2-1
MM61211,0000999 -19-12SEP12-2/24
080913
PN=111
Miscellaneous—Operational Checkout
Monitor and Gauge
Circuit Check
T216977 —UN—04NOV05
1— Coolant Temperature Gauge
2— Fuel Gauge
3— Monitor Display
4— Set Switch
5— Display Select Switch
6— Fast Travel Mode Indicator
7— Engine Pre-Heat Indicator
8— Alternator Voltage Indicator
9— Low Fuel Level Indicator
10— High Coolant Temperature Indicator
11— Engine Oil Pressure Indicator
12— System Failure Indicator
NOTE: Monitor alarm is not checked during this procedure.
If engine coolant temperature is below 20°C (68°F), the first segment will
flash. Run engine a few minutes to warm coolant before check.
Engine OFF.
Key switch ON.
LOOK: Do engine coolant temperature gauge (1) and fuel gauge (2) segments come
on?
YES: Go to next check.
LOOK: Do all monitor lights come on, and after 2—3 seconds, only the alternator
indicator and engine oil pressure indicator light remain on?
NO: Check fuse F9.
Continued on next page
4-2-2
Go to your authorized
dealer.
MM61211,0000999 -19-12SEP12-3/24
080913
PN=112
Miscellaneous—Operational Checkout
Engine Pre-Heat Circuit
Check
T204921 —UN—03DEC04
T102341 —UN—29AUG96
1— HEAT
2— OFF
3— ON
4— START
Turn and hold the key switch in HEAT position (1).
LOOK: Does the engine pre-heat indicator light come ON and then go OFF?
YES: Go to next check.
LOOK: Does the engine pre-heat indicator go OFF after 15 seconds?
NO: Check fuse F9.
Go to your authorized
dealer.
MM61211,0000999 -19-12SEP12-4/24
Travel Lever and Pedal
Neutral Check
T121794 —UN—16JUN99
Engine OFF.
Push each travel lever forward, then release.
Pull each travel lever rearward, then release.
FEEL: Does each lever have equal effort to operate forward and reverse?
YES: Go to next check.
FEEL/LOOK: Does each lever return to neutral at the same time when released?
NO: Go to your authorized
dealer.
Continued on next page
4-2-3
MM61211,0000999 -19-12SEP12-5/24
080913
PN=113
Miscellaneous—Operational Checkout
Light Circuit Check
T216979 —UN—04NOV05
Canopy Machine Shown
1— Work Light Switch
2— Travel Speed Control Switch
3— Travel Alarm Cancel Switch
NOTE: All accessories are powered from the fuse block. If any accessories
do not function, check fuses in fuse block.
Turn key switch ON.
Push work light switch (1) to turn on work lights.
LOOK: Are the work lights on the boom and left front corner of upperstructure ON?
Push work light switch to turn off the work lights.
YES: Go to next check.
LOOK: Do all the lights go OFF?
NO: Check fuse F5.
Go to your authorized
dealer.
Continued on next page
4-2-4
MM61211,0000999 -19-12SEP12-6/24
080913
PN=114
Miscellaneous—Operational Checkout
Wiper Circuit Check—Cab
Only
T217016 —UN—08NOV05
1— Wiper and Washer Switch
NOTE: Ensure upper front window is fully down and latched in place. Wiper interlock
switch will prevent operation if window is not in place.
Key switch ON.
Push wiper switch (1) to turn on the wiper.
LOOK: Does wiper operate continuously?
Push wiper switch to turn off wiper.
YES: Go to next check.
LOOK: Does wiper arm stop in park position at left side of window?
NO: Check fuse F6.
Go to your authorized
dealer.
MM61211,0000999 -19-12SEP12-7/24
Washer Circuit
Check—Cab Only
T217016 —UN—08NOV05
1— Wiper and Washer Switch
NOTE: Ensure upper front window is fully down and latched in place. Wiper interlock
switch will prevent operation if window is not in place.
Key switch ON.
Push wiper and washer switch (1) to activate washer motor.
LOOK: Does washer motor operate?
Push wiper and washer switch to turn on the wiper and activate the washer.
YES: Go to next check
LOOK: Do the washer motor and the wiper operate?
NO: Check fuse F6.
Go to your authorized
dealer.
Continued on next page
4-2-5
MM61211,0000999 -19-12SEP12-8/24
080913
PN=115
Miscellaneous—Operational Checkout
Horn Circuit Check
Key switch OFF.
Push horn button on top of right control lever.
YES: Go to next check.
LISTEN: Does horn sound?
NO: Check fuse F1.
Go to your authorized
dealer.
MM61211,0000999 -19-12SEP12-9/24
Operational Checks—Engine ON
Continued on next page
4-2-6
MM61211,0000999 -19-12SEP12-10/24
080913
PN=116
Miscellaneous—Operational Checkout
Monitor and Gauge
Circuit Check
T216977 —UN—04NOV05
1— Coolant Temperature Gauge
2— Fuel Gauge
3— Monitor Display
4— Set Switch
5— Display Select Switch
6— Fast Travel Mode Indicator
7— Engine Pre-Heat Indicator
8— Alternator Voltage Indicator
9— Low Fuel Level Indicator
10— High Coolant Temperature Indicator
11— Engine Oil Pressure Indicator
12— System Failure Indicator
Start engine.
LOOK: Do alternator voltage (8) and engine oil pressure (11) indicators go OFF after
engine starts?
LOOK: Do all monitor indicators remain OFF after engine starts?
IMPORTANT: Stop the engine if alternator or engine oil pressure indicators do
not go OFF, or a monitor indicator comes ON after engine starts.
NOTE: When the coolant temperature is lower than 20°C (68°F), the
first segment will flash.
LOOK: Are coolant temperature gauge (1) segments in normal operating zone after a
few minutes?
YES: Go to next check.
LOOK: Does fuel gauge (2) indicate fuel level?
NO: Check fluid levels.
Check fuses F11 and F9.
See Inspect Fan Belt, Check
and Adjust Tension to adjust
belt tension. (Section 3-5.)
Go to your authorized
dealer.
Continued on next page
4-2-7
MM61211,0000999 -19-12SEP12-11/24
080913
PN=117
Miscellaneous—Operational Checkout
Heater and Air
Conditioning Circuit
Check—If Equipped
T217015 —UN—09NOV05
1— Upper Vent and Defrost Button
2— Upper and Lower Vents and Defrost Button
3— Lower Vent Button
4— Blower Speed—Raise Button
5— Heater and Air Conditioning ON Button
6— Blower Speed—Lower Button
7— Temperature Control—Raise Button
8— Temperature Control—Lower Button
9— Air Conditioning ON/OFF Button
Engine running and at normal operating temperature.
Push heater and air conditioning ON button (5). Indicator next to button will light.
Push blower speed—raise button (4) to all three speeds.
YES: Go to next check.
FEEL/LISTEN: Does blower motor have three speeds?
NO: Check fuse F7.
Go to your authorized
dealer.
Push blower speed—raise button (4) to highest speed.
Push upper vent and defrost button (1).
FEEL: Does air flow through upper vents?
Push upper and lower vents and defrost button (2).
FEEL: Does air flow through upper and lower vents?
Push lower vent button (3).
YES: Go to next check.
FEEL: Does air flow through lower vent?
NO: Check fuse F7.
Go to your authorized
dealer.
With heater and air conditioning ON button on (5), push temperature control—raise
button (7) to warmest position.
FEEL: Does warm air flow from vents?
Turn air conditioning ON/OFF button (9) on. Indicator next to button will light.
Move temperature control—lower button (8) to coolest position.
YES: Go to next check.
FEEL: Does cool air flow from vents?
NO: Check fuses F2 and
F7.
Go to your authorized
dealer.
Continued on next page
4-2-8
MM61211,0000999 -19-12SEP12-12/24
080913
PN=118
Miscellaneous—Operational Checkout
Pilot Control Shut-Off
Switch Check
T205926 —UN—10DEC04
CAUTION: Prevent possible injury from unexpected machine movement.
Machine will move during this check. Make sure area is clear and large
enough to operate all machine functions. Keep bystanders clear of the area.
Run engine at slow idle.
Pilot control shut-off lever in LOCKED (rearward) position (1).
Actuate all dig and travel function controls.
YES: Go to your authorized
dealer.
LOOK: Do any dig or travel functions operate?
NO: Go to next step in this
check.
T205927 —UN—10DEC04
Move pilot control shut-off lever to UNLOCKED position (forward) (1).
Actuate all dig and travel functions.
YES: Go to next check.
LOOK: Do all functions operate?
NO: Go to your authorized
dealer.
MM61211,0000999 -19-12SEP12-13/24
Travel Alarm Circuit
Check
CAUTION: Prevent possible injury from unexpected machine movement.
Machine will move during this check. Make sure area is clear and large
enough to operate all machine functions. Keep bystanders clear of the area.
Engine running.
Pilot control shut-off lever in UNLOCKED position (forward).
Push travel levers or pedals forward for forward travel.
LISTEN: Does travel alarm sound?
Pull levers or push travel pedals rearward for reverse travel.
LISTEN: Does travel alarm sound?
Pilot control shut-off lever in UNLOCKED position (forward).
Push travel levers or pedals forward for forward travel.
Press and release the travel alarm cancel switch.
YES: Go to next check.
LISTEN: Does the travel alarm stop?
NO: Check fuses F8 and
F9.
Go to your authorized
dealer.
Continued on next page
4-2-9
MM61211,0000999 -19-12SEP12-14/24
080913
PN=119
Miscellaneous—Operational Checkout
Hydraulic Oil Tank
Pressurization Check
Engine running.
Raise boom to full height, then lower boom to ground.
Engine OFF.
Slowly loosen cap on hydraulic oil tank.
LISTEN: Is air heard escaping?
YES: Go to next check.
IMPORTANT: Avoid pump damage. The pressurized hydraulic oil tank creates
pressure at the inlet to the hydraulic pumps. If filler cap does not
seal, hydraulic pumps could cavitate and be damaged.
NO: Replace cap.
MM61211,0000999 -19-12SEP12-15/24
Pilot Controller Pattern
Check—SAE Backhoe
Pattern
CAUTION
FAMILIARIZE YOURSELF WITH THE PATTERN
SELECTED BY OPERATING SLOWLY.
Excavator Pattern
Backhoe Pattern
5
4
T205929
T205929 —19—15DEC04
T205091 —UN—01DEC04
1— Pilot Control Pattern Lever Selector
2— Excavator Position
3— Backhoe Position
4— Excavator Pattern
5— Backhoe Pattern
CAUTION: Prevent possible injury from unexpected machine movement.
Machine will move during this check. Make sure area is clear and large
enough to operate all machine functions. Keep bystanders clear of the area.
Run engine at slow idle.
Operate machine in clear area.
Move pilot control pattern lever selector (1) to backhoe position (3).
Push pilot shut-off lever to UNLOCKED position. Slowly move control levers to all
backhoe positions (5) on decal.
YES: Go to next check.
LOOK: Do bucket, boom, arm, and swing move as shown on decals?
NO: Check pilot controller
pattern conversion valve
position.
Go to your authorized
dealer.
Continued on next page
4-2-10
MM61211,0000999 -19-12SEP12-16/24
080913
PN=120
Miscellaneous—Operational Checkout
Pilot Controller Pattern
Check—ISO Excavator
Pattern
CAUTION
FAMILIARIZE YOURSELF WITH THE PATTERN
SELECTED BY OPERATING SLOWLY.
Excavator Pattern
Backhoe Pattern
5
4
T205929
T205929 —19—15DEC04
T205091 —UN—01DEC04
1— Pilot Control Pattern Lever Selector
2— Excavator Position
3— Backhoe Position
4— Excavator Pattern
5— Backhoe Pattern
CAUTION: Prevent possible injury from unexpected machine movement.
Machine will move during this check. Make sure area is clear and large
enough to operate all machine functions. Keep bystanders clear of the area.
Run engine at slow idle.
Operate machine in clear area.
Move pilot control pattern lever selector (1) to excavator position (2).
Push pilot shut-off lever to UNLOCKED position. Slowly move control levers to all
excavator positions (4) on decal.
YES: Go to next check.
LOOK: Do bucket, boom, arm, and swing move as shown on decals?
NO: Check pilot controller
pattern conversion valve
position.
Go to your authorized
dealer.
Continued on next page
4-2-11
MM61211,0000999 -19-12SEP12-17/24
080913
PN=121
Miscellaneous—Operational Checkout
Swing Dynamic Braking
Check
T6479AY —UN—19OCT88
CAUTION: Prevent possible injury from unexpected machine movement.
Machine will move during this check. Make sure area is clear and large
enough to operate all machine functions. Keep bystanders clear of the area.
Position upperstructure with boom in front.
Extend arm and curl the bucket. Lower boom so bucket pivot pin is at the same level as
boom-to-main frame pin.
Run engine at fast idle.
Actuate swing control valve to full stroke. Swing around 90 degrees (1/4 turn) and
then release lever.
LOOK: Does upperstructure stop within 45 degrees (1/8 turn) after releasing lever?
YES: Go to next check.
Repeat procedure in opposite direction.
NO: Go to your authorized
dealer.
MM61211,0000999 -19-12SEP12-18/24
Dig Function Drift Check
T6290AF —UN—19OCT88
CAUTION: Prevent possible injury from unexpected machine movement.
Machine will move during this check. Make sure area is clear and large
enough to operate all machine functions. Keep bystanders clear of the area.
Run engine at slow idle.
Fill bucket with dirt. Position bucket at maximum reach with bucket 50 mm (2 in.)
above ground.
Observe bucket for 1 minute.
YES: Go to your authorized
dealer.
LOOK: Does bucket drift down to ground within 1 minute?
NO: Go to next check.
Continued on next page
4-2-12
MM61211,0000999 -19-12SEP12-19/24
080913
PN=122
Miscellaneous—Operational Checkout
Travel System Tracking
Check
T216979 —UN—04NOV05
1— Work Light Switch
2— Travel Speed Control Switch
3— Travel Alarm Cancel Switch
CAUTION: Prevent possible injury from unexpected machine movement.
Machine will move during this check. Make sure area is clear and large
enough to operate all machine functions. Keep bystanders clear of the area.
Engine at fast idle.
Press upper half (rabbit) of travel speed control switch (2).
6
8
7
5
6
TX1120481 —UN—17AUG12
Tracking Check
5— Distance of Mistrack
6— Acceleration and Deceleration Zone (approximately): 3—5 m (10—16 ft.)
7— Test Line (distance): 20 m (66 ft.)
8— Track Print
Operate machine at full travel forward speed on a flat and level surface approximately
30 m (99 ft.).
NOTE: When machine mistracks right, hydraulic pump 1 circuit oil flow may be
less than specification. When machine mistracks left, hydraulic pump
2 circuit oil flow may be less than specification.
Observe direction of mistrack.
Create a straight test line 20 m (66 ft.) (7) long between two points on track print (8).
Continued on next page
4-2-13
MM61211,0000999 -19-12SEP12-20/24
080913
PN=123
Miscellaneous—Operational Checkout
Measure and record greatest distance of mistrack (5) between inside edge of track
print and test line.
Repeat procedure in reverse travel.
YES: Go to your authorized
dealer.
LOOK: Does machine mistrack excessively?
NO: Go to next check.
MM61211,0000999 -19-12SEP12-21/24
Travel System Tracking
Checks While Operating
a Dig Function
T216979 —UN—04NOV05
1— Work Light Switch
2— Travel Speed Control Switch
3— Travel Alarm Cancel Switch
CAUTION: Prevent possible injury from unexpected machine movement.
Machine will move during this check. Make sure area is clear and large
enough to operate all machine functions. Keep bystanders clear of the area.
Engine at fast idle.
Press upper half (rabbit) of travel speed control switch (2).
Travel machine at full speed forward on a flat and level area.
NOTE: Machine will slow down during this test.
After machine is moving, slowly move the arm control lever from neutral to full actuation YES: Go to your authorized
to extend the arm.
dealer.
LOOK: Does machine mistrack excessively when the arm is extended?
Continued on next page
4-2-14
NO: Go to next check.
MM61211,0000999 -19-12SEP12-22/24
080913
PN=124
Miscellaneous—Operational Checkout
Travel Speed Change
Check
T216979 —UN—04NOV05
1— Work Light Switch
2— Travel Speed Control Switch
3— Travel Alarm Cancel Switch
CAUTION: Prevent possible injury from unexpected machine movement.
Machine will move during this check. Make sure area is clear and large
enough to operate all machine functions. Keep bystanders clear of the area.
Run engine at fast idle.
Ensure travel speed control switch (2) is in slow speed (turtle).
Actuate travel function to full speed forward.
Push travel speed control switch (2) to fast speed (rabbit).
YES: Go to next check.
FEEL/LOOK: Does machine travel speed increase?
NO: Go to your authorized
dealer.
MM61211,0000999 -19-12SEP12-23/24
Blade Function Check
CAUTION: Prevent possible injury from unexpected machine movement.
Machine will move during this check. Make sure area is clear and large
enough to operate all machine functions. Keep bystanders clear of the area.
Run engine at slow idle.
Pull blade control lever rearward.
LOOK: Does blade rise?
Release lever.
LOOK: Does lever return to neutral and the blade stop?
Push lever forward.
LOOK: Does blade lower?
Release lever.
YES: Operational checkout
complete.
LOOK/FEEL: Does lever return to neutral and the blade stop?
NO: Go to your authorized
dealer.
MM61211,0000999 -19-12SEP12-24/24
4-2-15
080913
PN=125
Miscellaneous—Troubleshooting
Using Troubleshooting Charts
NOTE: Troubleshooting charts are arranged from the
simplest to verify, to least likely, more difficult
to verify. When diagnosing a problem, use
all possible means to isolate the problem to a
single component or system. Use the following
steps to diagnose problems:
Step 2. Troubleshooting charts.
Step 3. Adjustments.
Step 4. See your authorized dealer.
Step 1. Operational Checkout Procedure.
TX,FF,105 -19-27FEB02-1/1
4-3-1
080913
PN=126
Miscellaneous—Troubleshooting
Engine
Symptom
Problem
Solution
Engine Cranks But Will Not Start Or No fuel
Hard To Start
Wrong fuel
Add fuel.
Use correct fuel.
Fuel filter clogged
Replace filter. Bleed air.
Water separator clogged or not primed Check water separator.
Engine Knocks, Runs Irregularly,
Or Stops
Water in fuel
Check, drain fuel tank , and refill.
Leaks in fuel system
Check fuel system connections. See
your authorized dealer.
Contaminated fuel
Drain tank. Add clean fuel. Check
water separator.
Air in fuel system
Bleed air.
Low battery power
Charge or install new battery.
Slow cranking speed (poor electrical
connection)
Clean and tighten battery and starter
connections.
Wrong engine oil
Use correct oil.
Air filter clogged
Clean or replace element.
Starter
Replace starter.
Air filter clogged
Clean or replace element.
Fuel filter clogged
Replace filter. Bleed air.
Water separator clogged
Check water separator.
Air in water separator
Bleed air from fuel system.
Engine oil level low
Add oil.
Contaminated fuel
Drain tank. Add clean fuel. Replace
water separator.
Air in fuel system
Bleed air from fuel system.
Coolant temperature low
Check for proper thermostat
temperature and operation. Replace if
necessary.
Injection pump
See your authorized dealer.
Continued on next page
4-3-2
OUO1032,00015BB -19-06JUN08-1/3
080913
PN=127
Miscellaneous—Troubleshooting
Symptom
Problem
Solution
Engine Starts But Will Not Continue No fuel flow to engine
To Run
Engine Not Developing Full Power Air filters clogged
Engine Overheats
Low Engine Oil Pressure
Check and replace fuse F9.
Clean or replace filter element.
Fuel filter clogged
Change filter. Bleed air.
Water separator
Change.
Contaminated fuel
Drain tank. Change water separator,
change fuel filter, bleed air. Add clean
fuel.
Wrong fuel
Use correct fuel.
Fuel line clogged
Repair or replace fuel line. Bleed air.
Clogged vent in fuel tank cap
Clean or install new cap.
Exhaust restriction
Install new muffler.
Wrong valve clearance
Check and adjust valves.
Wrong oil
Use correct oil.
Coolant level low
Add coolant to recovery tank. Remove
cap when cool. Check coolant level
in radiator.
Radiator screen clogged
Remove and clean screen.
Radiator core or oil cooler core
clogged
Air filter clogged
Clean radiator and oil cooler.
Radiator cap
Go to your authorized dealer.
Fan on backwards
Install fan correctly.
Cooling system passages clogged
Flush cooling system.
Oil level low
Add oil.
Oil filter clogged
Install new oil filter.
Wrong oil
Use correct oil.
Oil leaks
Go to your authorized dealer.
Engine temperature too high
Check cooling system.
Continued on next page
4-3-3
Clean or replace element. Check inlet
screen.
OUO1032,00015BB -19-06JUN08-2/3
080913
PN=128
Miscellaneous—Troubleshooting
Symptom
Problem
Solution
Engine Uses Too Much Oil
Wrong oil
Use correct oil.
Oil leaks
Check engine oil drain plug.
Engine temperature too high
Check cooling system.
Air cleaner clogged
Clean element or install new element.
Clogged or dirty air intake system
Clean air intake system.
Wrong fuel
Use correct fuel.
Wrong fuel
Use correct fuel.
Clogged or dirty air intake or exhaust
system
Wrong fuel
Clean air intake and exhaust system.
Use correct fuel.
Cold engine
Run engine until warm.
Engine Uses Too Much Fuel
Excessive Black Or Gray Exhaust
Smoke
Exhaust Smoke Is White
OUO1032,00015BB -19-06JUN08-3/3
4-3-4
080913
PN=129
Miscellaneous—Troubleshooting
Electrical System
Symptom
Problem
Solution
Nothing Works
Battery
Recharge or replace.
Battery Undercharged
Loose or corroded connections
Clean and tighten connections or
replace battery.
Battery Will Not Take A Charge
Loose or corroded connections
Clean and tighten.
Low battery power
Replace battery.
Cracked battery case
Replace battery.
High ambient temperature
Refill with water.
No battery hold down clamp
Replace battery and install hold down
clamp.
Loose battery hold down clamp
Replace battery and install hold down
clamp.
Frozen battery
Replace battery. Keep battery fully
charged in cold weather.
Low water level
Add water.
Dirty or wet battery top, causing
discharge
Corroded or loose battery cables
Clean and wipe battery top dry.
Battery Uses Too Much Water
Cracked Battery Case
Low Battery Output
Starter Will Not Turn
Clean and tighten battery cables.
Broken battery post
Wiggle battery post by hand. If post
wiggles or turns, replace battery.
Battery undercharged or dead
Recharge or replace battery.
Battery cables making poor
connections
Starter
Clean connections.
Repair or replace starter.
Starter pinion jammed in flywheel gear Repair or replace starter or ring gear.
Starter Turns But Will Not Crank
Engine
Engine Cranks Slowly
Starter
Repair or replace starter.
Battery cables damaged or broken
internally
Battery or starter cable connections
loose or corroded
Battery discharged or will not hold a
charge
Starter
Inspect and replace cables.
Low battery voltage
Recharge or replace battery.
Continued on next page
4-3-5
Clean and tighten connections.
Recharge or replace battery.
Repair or replace starter.
OUO1032,00015BC -19-17DEC08-1/2
080913
PN=130
Miscellaneous—Troubleshooting
Symptom
Problem
Solution
Starter Continues To Run After
Engine Starts
Starter
Repair or replace starter.
Key switch malfunction
Disconnect battery ground. See your
authorized dealer.
Loose or glazed alternator belt
Check belt. Replace if glazed.
Excessive electrical load from added
accessories
Remove accessories or install higher
output alternator.
Charging Indicator Light On,
Engine Running
Loose or corroded electrical
Inspect, clean, or tighten electrical
connections on battery, ground strap, connections.
starter, or alternator
Battery voltage low
Charge or replace battery.
Noisy Alternator
No Monitor Panel Indicators or
Gauges Work
Individual Indicators Not Working
In Monitor Panel
No Switch Panel Switches Work
Angle Blade Drift Too Great
Worn drive belt
Replace belt.
Worn pulleys
Replace pulleys and belt.
Pulley misaligned
Adjust alternator mount.
Alternator bearing
Loosen alternator belts. Turn pulley
by hand. If any roughness is felt,
repair alternator.
Fuse
Replace fuse F2 or F9.
Bulb
Replace bulb.
Fuse
Replace fuses F2 or F9.
Angle blade moves when blade is not Check lever switches.
operated
Check relays and fuses.
Check solenoids.
Angle Blade Not Operated
One side of angle blade does not work Check lever switches.
Check relays and fuses.
Check solenoids.
Angle Blade Moves Slowly
One side of angle blade does not work Check lever switches.
Check relays and fuses.
Check solenoids.
OUO1032,00015BC -19-17DEC08-2/2
4-3-6
080913
PN=131
Miscellaneous—Troubleshooting
Hydraulic System
Symptom
Problem
Solution
No Hydraulic Functions
Low hydraulic oil
Add oil.
Clogged suction filter
Clean.
Low oil level
Fill tank to full mark.
Wrong oil
Use correct oil.
Suction screen clogged
Inspect and clean.
Hydraulic tank cap
Replace cap.
Wrong oil
Use correct oil.
Clogged radiator or oil cooler
Clean and straighten fins.
Radiator screen clogged
Remove and clean.
Clogged filters
Install new filters.
Low oil level
Fill tank to full mark.
Contaminated oil
Drain oil and refill.
High or low oil level
Correct level.
Wrong oil
Use correct oil.
Water in oil
Change oil.
Kinks or dents in oil lines
Check lines.
No Swing Function
Pilot control hoses pinched or kinked
Inspect and correct.
Swing Function Is "Jerky"
Lack of grease
Fill with grease.
Slow Travel Speed only
Fuse
Replace fuse F8.
Inspect and correct.
Travel Is "Jerky"
Pilot controller hoses pinched or
kinked
Track sag adjustment
Adjust tension.
Rocks or mud jammed in track frame
Remove and repair.
Water separator clogged
Drain.
Hydraulic Functions Are Slow or
Have Little or No Power
Hydraulic Oil Overheats
Oil Foams
Engine Stops When Travel Or
Control Lever Moved
NOTE: If any other problems are encountered which
require special tools or machine knowledge to
correct, see your authorized dealer.
MM61211,0000A61 -19-18APR06-1/1
4-3-7
080913
PN=132
Miscellaneous—Storage
Prepare Machine for Storage
T47764 —UN—09NOV88
1. Repair worn or damaged parts. Install new parts, if
necessary, to avoid needless delays later.
2. Clean primary air cleaner.
IMPORTANT: High-pressure washing greater than
1379 kPa (13.8 bar) (200 psi) can damage freshly
painted finishes. Paint should be allowed to
air dry for 30 days minimum after receipt of
machine before cleaning parts or machines
with high pressure. Use low pressure wash
operations until 30 days have elapsed.
T5813AM —UN—09FEB89
3. Wash the machine. Use low-pressure wash operations
(less than 1379 kPa [13.8 bar] [200 psi] until 30 days
after receipt of machine have elapsed. Paint areas to
prevent rust. Replace decals, where needed.
4. Steel tracks: Apply waste oil to track chains. Run
machine back and forth several times. Park machine
on a hard surface to prevent tracks from freezing to
ground.
5. Store machine in a dry, protected place. If stored
outside, cover with a waterproof material.
8. Lubricate all grease points.
IMPORTANT: LPS 3 Rust Inhibitor can destroy
painted finish. DO NOT spray LPS 3 Rust
Inhibitor on painted areas.
9. Remove battery.
10. Remove perishable items.
6. Retract all hydraulic cylinders, if possible. If not, coat
exposed cylinder rods with LPS ® 3 Rust Inhibitor.
11. Remove keys and lock all covers and doors.
7. Place a "DO NOT OPERATE" tag on the right control
lever.
LPS is a trademark of the Holt Lloyd Corporation.
OUO1032,00015A7 -19-18APR06-1/1
CAUTION: Prevent possible injury or death
from asphyxiation. Engine exhaust fumes
can cause sickness or death. Start engine
ONLY in a well-ventilated area.
1. Drain water and sediment from fuel tank when air
temperature is above freezing.
2. Remove LPS 3® Rust Inhibitor from cylinder rods with
a cleaning solvent.
T6191AA —UN—18OCT88
Monthly Storage Procedure
LPS 3 Rust Inhibitor is a trademark of Illinois Tool Works.
Continued on next page
4-4-1
VD76477,00016A3 -19-13JUN11-1/2
080913
PN=133
Miscellaneous—Storage
T6181AU —UN—18OCT88
IMPORTANT: Prevent possible engine damage.
During cold temperatures, check fluidity of
engine oil on dipstick. If the oil appears waxy
and/or jelly-like rather than liquid, DO NOT
attempt to start engine. Use external heat source
to warm the crankcase until oil appears fluid.
3. Check all fluid levels. If low, check for leaks and add
oil as required.
4. Check belts.
5. Check condition of all hoses and connections.
6. Check battery electrolyte level. Charge and install
battery.
7. For machines with tires, check condition of tires and
tire pressure.
For machines with tracks, check condition of tracks
and track sag.
On crawler machines with non sealed-and-lubricated
track chains, apply oil to the pin-to-bushing joints. Run
machine back and forth several times.
8. Park machine on a hard surface to prevent tracks from
freezing to ground.
9. Fill fuel tank.
run until it reaches operating temperature. Run at 1/2
speed for five minutes. Do not run at fast or slow idle.
• If engine fails to start or runs poorly after starting,
change fuel filter(s). Bleed fuel system.
12. Operate all controls, levers, seat adjustments, etc.
CAUTION: Prevent possible injury from
unexpected machine movement. Clear the
area of all persons before running machine
through the operation procedure.
13. Make sure the area is clear to allow for movement.
Cycle all hydraulic functions several times. Check
condition of all hoses and connections.
10. Pre-lubricate turbocharger bearings, if equipped:
a. Disconnect fuel shutoff fuse.
14. Park the machine with cylinder rods retracted, if
possible. Turn key switch to OFF.
b. Crank engine for 10 seconds.
c. Connect fuel shutoff fuse.
11. Inspect engine compartment, and remove any foreign
material that may have accumulated. Start engine and
15. Apply LPS 3 Rust Inhibitor to exposed cylinder rod
areas.
VD76477,00016A3 -19-13JUN11-2/2
4-4-2
080913
PN=134
Miscellaneous—Serial Numbers
Record Product Identification Number (PIN)
Purchase Date
T205214A —UN—24NOV04
PIN
NOTE: Record all 13 characters of the Product
Identification Number.
1— Product Identification
Number
OUO1032,00015AA -19-24NOV04-1/1
Record Engine Serial Number
Engine Serial Number (1)
T205429A —UN—29NOV04
1— Engine Serial Number
Top of Engine Shown
MM61211,000099A -19-08NOV05-1/1
1. Maintain in a secure location an up-to-date inventory
of all product and component serial numbers.
2. Regularly verify that identification plates have not
been removed. Report any evidence of tampering to
law enforcement agencies and order duplicate plates.
3. Other steps you can take:
- Mark your machine with your own numbering system
- Take color photographs from several angles of each
machine
TS1680 —UN—09DEC03
Keep Proof of Ownership
DX,SECURE1 -19-18NOV03-1/1
4-5-1
080913
PN=135
Miscellaneous—Serial Numbers
1. Install vandal-proof devices.
2. When machine is in storage:
- Lower equipment to the ground
- Set wheels to widest position to make loading more
difficult
- Remove any keys and batteries
3. When parking indoors, put large equipment in front of
exits and lock your storage buildings.
4. When parking outdoors, store in a well-lighted and
fenced area.
5. Make note of suspicious activity and report any thefts
immediately to law enforcement agencies.
6. Notify your John Deere dealer of any losses.
TS230 —UN—24MAY89
Keep Machines Secure
DX,SECURE2 -19-18NOV03-1/1
4-5-2
080913
PN=136
Miscellaneous—Specifications
Engine Specifications
Item
Measurement
Specification
Yanmar 3TNV88
Type
Cylinders
Displacement
4 Cycle Water Cooled
3
1.642 L
100 cu in.
19.7 kW
26.4 hp Net SAE
Power at 2200 rpm
Electrical system
12 volt
MM61211,000099B -19-14DEC05-1/1
Drain and Refill Capacities
Item
Measurement
Specification
Fuel Tank
Capacity
40 L
10.6 gal
Cooling System (S.N. —254999)
Capacity
5.2 L
5.5 qt
Cooling System (S.N. 255000— )
Capacity
5.0 L
5.3 qt
Engine
Oil Capacity, Including Filter Change
7.2 L
7.6 qt
Hydraulic Tank (S.N. —254999)
Oil Capacity
35 L
9.2 gal
Hydraulic Tank (S.N. 255000— )
Oil Capacity
32 L
8.5 gal
Travel Gearbox (each)
Oil Capacity
0.6 L
0.63 qt
MM61211,000099C -19-22DEC08-1/1
4-6-1
080913
PN=137
Miscellaneous—Specifications
T205725 —UN—07DEC04
Machine Specifications
1— Overall Upperstructure Width 4— Minimum Ground Clearance
2— Machine Height
5— Counterweight Clearance
3— Rear End Swing Radius
6— Engine Cover Height
7— Undercarriage Length
8— Undercarriage Width
9— Sprocket Center to Idler
Center
NOTE: Specifications and design are subject to change
without notice. Wherever applicable, specifications
are in accordance with PCSA and SAE standards.
Except where otherwise noted, these specifications
are based on a machine equipped with 300 mm
10— Track Shoe Width
(12 in.) shoes, 1.17 m (3 ft 10 in.) arm, 0.09
m3 (0.12 yd3) bucket, full fuel tank 79 kg (175
lb) operator standard counterweight 292 kg (644
lb), and standard equipment.
Item
Measurement
Specification
1—Overall Upperstructure Width
Distance
1,550 mm
5 ft 1 in.
2—Machine Height
Transport Height—Canopy
2,460 mm
8 ft 1 in.
2,500 mm
8 ft 2 in.
Transport Height—Cab
3—Rear End Swing Radius
Distance—Standard Counterweight
Distance—Additional Counterweight
775 mm
2 ft 7 in.
870 mm
2 ft 10 in.
4—Minimum Ground Clearance
Distance
320 mm
1 ft 6 in.
5—Counterweight Clearance
Distance
560 mm
1 ft 10 in.
6— Engine Cover
Height
1420 mm
4 ft 8 in.
Continued on next page
4-6-2
MM61211,000099D -19-15DEC05-1/2
080913
PN=138
Miscellaneous—Specifications
Item
Measurement
Specification
7—Undercarriage
Length
1950 mm
6 ft 5 in.
8—Undercarriage
Width
1550 mm
5 ft 1 in.
9—Sprocket Center to Idler Center
Distance
1490 mm
4 ft 11 in.
10—Track Shoe
Width
300 mm
12 in.
Item
Measurement
Specification
Machine with Standard Arm and
Standard Counterweight
Operating Weight—Canopy
2800 kg
6,160 lb
2950 kg
6490 lb
Operating Weight—Cab
Machine with Long Arm and
Additional Counterweight
Operating Weight—Canopy
Operating Weight—Cab
3,010 kg
6620 lb
3160 kg
6950 lb
MM61211,000099D -19-15DEC05-2/2
4-6-3
080913
PN=139
Miscellaneous—Specifications
T121258 —UN—22APR99
Working Ranges
1— Maximum Digging Reach
2— Maximum Digging Depth
3— Maximum Cutting Height
4— Maximum Dumping Height
5— Transport Height
9— Blade Bottom Lowest
6— Overall Transport Length
Position (below ground level)
7— Minimum Swing Radius
10— Boom Offset (left)
8— Blade Bottom Highest
11— Boom Offset (right)
Position (above ground level)
Item
Measurement
Specification
1—Maximum Digging Reach
Distance—Canopy or Cab
4670 mm
15 ft 4 in.
4920 mm
Distance—Long Arm and Additional
Counterweight
16 ft 2 in.
2—Maximum Digging Depth
Canopy or Cab
2590 mm
8 ft 6 in.
Long Arm and Additional Counterweight2890 mm
9 ft 6 in.
3—Maximum Cutting Height
Canopy
Canopy, Long Arm and Additional
Counterweight
Cab
Cab, Long Arm and Additional
Counterweight
5760 mm
18 ft 11 in.
4550 mm
14 ft 11 in.
4290 mm
14 ft 1 in.
4350 mm
14 ft 3 in.
4—Maximum Dumping Height
Canopy
4080 mm
13 ft 5 in.
Continued on next page
4-6-4
MM61211,000099E -19-06JAN09-1/2
080913
PN=140
Miscellaneous—Specifications
Item
Measurement
Specification
Canopy, Long Arm and Additional
Counterweight
3300 mm
Height—Cab
Cab, Long Arm and Additional
Counterweight
10 ft 10 in.
3030 mm
9 ft 11 in.
3120 mm
10 ft 3 in.
5—Machine—Rubber Track
Transport Height—Canopy
Transport Height—Cab
6—Machine
Transport Length—Canopy or Cab
Transport Length—Long Arm and
Additional Counterweight
2460 mm
8 ft 1 in.
2500 mm
8 ft 2 in.
4200 mm
13 ft 9 in.
4280 mm
14 ft 1 in.
7—Minimum Swing
Radius—Canopy
Radius—Canopy, Long Arm and
Additional Counterweight
Radius—Cab
1960 mm
6 ft 5 in.
2040 mm
6 ft 8 in.
2050 mm
6 ft 9 in.
Radius—Cab, Long Arm and Additional2100 mm
Counterweight
6 ft 11 in.
8—Blade Bottom Highest Position
(above ground level)
Distance
360 mm
1 ft 2 in.
9—Blade Bottom Lowest Position
(below ground level)
Distance
315 mm
1 ft
10—Offset Distance (right)
Maximum Distance—Canopy
640 mm
2 ft 1 in.
600 mm
2 ft
Maximum Distance—Cab
11—Offset Distance (left)
Maximum Distance
705 mm
2 ft 4 in.
MM61211,000099E -19-06JAN09-2/2
4-6-5
080913
PN=141
Miscellaneous—Specifications
Excavator Lift Capacity
(Blade on the Ground With Standard Boom and Canopy)
Rubber Track
Load Radius
1.5 m
5 ft
Load Point
Height
m
ft
At Maximum
Reach
Side
Front
Side
Front
@m
@ft
1.5 m
5 ft
453 kg
998 lb
787 kg*
1735 lb*
232 kg
512 lb
395 kg*
870 lb*
4.48 m
14 ft 8 in.
0
Ground
409 kg
902 lb
1158 kg*
2554 lb*
249 kg
549 lb
488 kg*
1076 lb*
4.20 m
13 ft 10 in.
416 kg
917 lb
870 kg*
1917 lb*
-1.5 m
-5 ft
Side
1329 kg
2930 lb
Front
3 m
10 ft
1650 kg*
3637 lb*
Steel Track
Load Radius
1.5 m
5 ft
Load Point
Height
m
ft
At Maximum
Reach
Side
Front
Side
Front
@m
@ft
1.5 m
5 ft
471 kg
1038 lb
787 kg*
1735 lb*
244 kg
537 lb
395 kg*
870 lb*
4.48 m
14 ft 8 in.
0
Ground
427 kg
941 lb
1158 kg*
2554 lb*
261 kg
575 lb
488 kg*
1076 lb*
4.20 m
13 ft 10 in.
434 kg
956 lb
870 kg*
1917 lb*
-1.5 m
-5 ft
Side
1378 kg
3038 lb
Front
3 m
10 ft
1650 kg*
3637 lb*
NOTE: Ratings are at bucket lift hook, using standard counterweight, situated on firm, level, uniform supporting surface.
Figures do not exceed 87 percent of hydraulic capacity or 75 percent of weight needed to tip machine. Figures marked with
an (*) are hydraulically limited capacities. Remaining figures are stability-limited capacities.
DW90712,00000F4 -19-09JAN09-1/1
4-6-6
080913
PN=142
Miscellaneous—Specifications
Excavator Lift Capacity
(Blade on the Ground With Long Arm and Canopy)
IMPORTANT: Using the Long Arm requires
additional counterweight.
Rubber Track
Load Radius
1.5 m
5 ft
Load Point
Height
m
ft
At Maximum
Reach
Side
Front
Side
Front
@m
@ft
1.5 m
5 ft
544 kg
1199 lb
661 kg*
1457 lb*
258 kg
568 lb
364 kg*
802 lb*
4.72 m
15 ft 6 in.
0
Ground
489 kg
1079 lb
1112 kg*
2453 lb*
271 kg
599 lb
451 kg*
996 lb*
4.48 m
14 ft 8 in.
485 kg
1070 lb
1011 kg*
2228 lb*
-1.5 m
-5 ft
Side
1524 kg
3361 lb
Front
3 m
10 ft
1649 kg*
3678 lb*
Steel Track
Load Radius
1.5 m
5 ft
Load Point
Height
m
ft
At Maximum
Reach
Side
Front
Side
Front
@m
@ft
1.5 m
5 ft
562 kg
1238 lb
661 kg*
1457 lb*
268 kg
591 lb
364 kg*
802 lb*
4.72 m
15 ft 6 in.
0
Ground
508 kg
1119 lb
1113 kg*
2453 lb*
283 kg
623 lb
452 kg*
996 lb*
4.48 m
14 ft 8 in.
503 kg
1109 lb
1011 kg*
2228 lb*
-1.5 m
-5 ft
Side
1574 kg
3470 lb
Front
3 m
10 ft
1649 kg*
3635 lb*
NOTE: Ratings are at bucket lift hook, situated on firm, level, uniform supporting surface.
Figures do not exceed 87 percent of hydraulic capacity or 75 percent of weight needed to tip machine. Figures marked with
an (*) are hydraulically limited capacities. Remaining figures are stability-limited capacities.
DW90712,000030A -19-09JAN09-1/1
4-6-7
080913
PN=143
Miscellaneous—Specifications
Excavator Lift Capacity
(Blade on the Ground With Standard Boom and Cab)
Rubber Track
Load Radius
1.5 m
5 ft
Load Point
Height
m
ft
At Maximum
Reach
Side
Front
Side
Front
@m
@ft
1.5 m
5 ft
484 kg
1066 lb
787 kg*
1735 lb*
252 kg
555 lb
395 kg*
870 lb*
4.48 m
14 ft 8 in.
0
Ground
440 kg
970 lb
1158 kg*
2554 lb*
269 kg
594 lb
488 kg*
1076 lb*
4.20 m
13 ft 10 in.
447 kg
985 lb
870 kg*
1917 lb*
-1.5 m
-5 ft
Side
1414 kg
3117 lb
Front
3 m
10 ft
1650 kg*
3637 lb*
Steel Track
Load Radius
1.52 m
5 ft
Load Point
Height
m
ft
At Maximum
Reach
Side
Front
Side
Front
@m
@ft
1.52 m
5 ft
501 kg
1105 lb
787 kg*
1735 lb*
263 kg
579 lb
395 kg*
870 lb*
4.48 m
14 ft 8 in.
0
Ground
458 kg
1009 lb
1158 kg*
2554 lb*
282 kg
621 lb
488 kg*
1076 lb*
4.20 m
13 ft 10 in.
464 kg
1024 lb
870 kg*
1917 lb*
-1.52 m
-5 ft
Side
1463 kg
3226 lb
Front
3 m
10 ft
1650 kg*
3637 lb*
NOTE: Ratings are at bucket lift hook, using standard counterweight, situated on firm, level, uniform supporting surface.
Figures do not exceed 87 percent of hydraulic capacity or 75 percent of weight needed to tip machine. Figures marked with
an (*) are hydraulically-limited capacities. Remaining figures are stability-limited capacities.
DW90712,00000F5 -19-09JAN09-1/1
4-6-8
080913
PN=144
Miscellaneous—Specifications
Excavator Lift Capacity
(Blade on the Ground With Long Arm and Cab)
IMPORTANT: Using the Long Arm requires
additional counterweight.
Rubber Track
Load Radius
1.5 m
5 ft
Load Point
Height
m
ft
At Maximum
Reach
Side
Front
Side
Front
@m
@ft
1.5 m
5 ft
506 kg
1116 lb
487 kg*
1456 lb*
236 kg
520 lb
364 kg*
802 lb*
4.72 m
15 ft 6 in.
0
Ground
453 kg
998 lb
433 kg*
2455 lb*
249 kg
548 lb
452 kg*
996 lb*
4.48 m
14 ft 8 in.
448 kg
988 lb
1012 kg*
2231 lb*
-1.5 m
-5 ft
Side
1423 kg
3137 lb
Front
3 m
10 ft
1668 kg*
3678 lb*
Steel Track
Load Radius
1.52 m
5 ft
Load Point
Height
m
ft
At Maximum Reach
Side
Front
Side
Front
@m
@ft
1.52 m
5 ft
592 kg
1306 lb
661 kg*
1457 lb*
286 kg
631 lb
364 kg*
802 lb*
4.72 m
15 ft 6 in.
0
Ground
538 kg
1186 lb
1113 kg*
2453 lb*
302 kg
665 lb
452 kg*
996 lb*
4.48 m
14 ft 8 in.
534 kg
1177 lb
1011 kg*
2228 lb*
-1.52 m
-5 ft
Side
1659 kg
3657 lb
Front
3 m
10 ft
1668 kg*
3678 lb*
NOTE: Ratings are at bucket lift hook, situated on firm, level, uniform supporting surface.
Figures do not exceed 87 percent of hydraulic capacity or 75 percent of weight needed to tip machine. Figures marked with
an (*) are hydraulically-limited capacities. Remaining figures are stability-limited capacities.
DW90712,00000F6 -19-09JAN09-1/1
4-6-9
080913
PN=145
Miscellaneous—Specifications
4-6-10
080913
PN=146
Index
Page
Page
A
Acid burns.................................................................. 4-1-4
Adjustment
Belt tension ............................................................ 3-5-3
Engine valve lash (clearance)................................ 3-8-3
Seat...................................................................... 2-1-10
Track sag ............................................................... 3-4-7
Air cleaner element.................................................... 3-7-3
Clean...................................................................... 3-3-1
Air conditioning
Filter screens ......................................................... 4-1-8
Alternator ................................................................... 3-8-3
Indicator ................................................................. 2-1-2
Precaution.............................................................. 4-1-1
Voltage indicator .................................................... 2-1-1
Attachments
Adding safely ......................................................... 1-3-4
Operating safely..................................................... 1-3-4
Auxiliary line selector valve ....................................... 2-2-9
Auxiliary lines
Connecting and disconnecting............................... 4-1-6
Auxiliary pedal ........................................................... 2-2-8
Auxiliary power outlet ................................................ 4-1-5
B
Backover accidents
Avoiding ................................................................. 1-3-3
Battery
Charger .................................................................. 4-1-4
Explosion ............................................................... 4-1-4
Handling, checking, and servicing ......................... 4-1-2
Specification........................................................... 4-1-4
Battery explosions
Prevent................................................................... 1-2-5
Before starting work................................................... 2-2-1
Belt
Tension adjust ........................................................ 3-5-3
Blade ....................................................................... 2-2-10
Blade function
Operational checks .............................................. 4-2-15
Blade pins
Lubricate ................................................................ 3-7-2
Bleed hydraulic system.............................................. 4-1-5
Bolt and screw torque values
Metric ................................................................... 4-1-13
Unified inch .......................................................... 4-1-12
Boom
Lower with engine stopped .................................. 2-2-12
Boom-swing
Pedal...................................................................... 2-2-8
Boost starting............................................................. 4-1-3
Breaker ...................................................................... 3-2-5
Bucket
Tooth replacement ................................................. 3-4-4
Bucket and link pins
Lubricate ................................................................ 3-5-1
C
Cab
Door release lever.................................................. 2-1-7
Cab guarding ............................................................. 1-2-2
Chemical products
Handling................................................................. 1-2-5
Connecting and disconnecting
Auxiliary lines ......................................................... 4-1-6
Control lever
Multi-function.......................................................... 2-2-7
Pattern conversion ................................................. 2-2-7
Universal joint ........................................................ 3-7-1
Control pattern operation........................................... 2-2-6
Converting track ...................................................... 4-1-12
COOL-GARD II test strips ......................................... 3-3-2
Coolant
Add coolant extender ...................................3-3-2, 3-8-3
Additional information .......................................... 3-1-13
Check...........................................................3-3-2, 3-8-3
Diesel engine
Light duty.......................................................... 3-1-10
Hose...........................................................3-9-1, 3-10-1
John Deere Cool-Gard II Coolant Extender ......... 3-1-11
Level recovery tank................................................ 3-4-4
Sample................................................................... 3-7-3
Supplemental additives........................................ 3-1-11
Test ..............................................................3-3-2, 3-8-3
Testing.................................................................. 3-1-14
Warm temperature climates................................. 3-1-12
Cooling
System drain ..............................................3-9-1, 3-10-1
System, fill..................................................3-9-2, 3-10-2
COOLSCAN PLUS test kit......................................... 3-3-2
Cover
Maintenance access .............................................. 3-2-2
Crusher...................................................................... 3-2-5
Cylinder ..................................................................... 4-1-1
D
Daily machine check.................................................. 2-2-1
Diesel fuel........................................................3-1-1, 3-1-3
Sample................................................................... 3-7-3
Diesel fuel, testing
Testing Diesel Fuel................................................. 3-1-4
Dig function drift
Operational checks .............................................. 4-2-12
Disconnecting and connecting
Auxiliary lines ......................................................... 4-1-6
Door
Engine access........................................................ 3-2-2
Drain and refill capacities .......................................... 4-6-1
Continued on next page
Index-1
080913
PN=1
Index
Page
Page
Drain Intervals for Diesel Engine Coolant
Diesel Engine Coolant, Drain Intervals ................ 3-1-10
Driving
Slopes .................................................................. 2-2-11
Driving metal pins ...................................................... 1-4-2
Tank sump drain..................................................... 3-4-2
Fuse
Color codes............................................................ 4-1-7
Replacing ............................................................... 4-1-7
G
E
Effect of Cold Weather on Diesel Engines
Diesel Engines, Cold Weather Effect..................... 3-1-5
Electrical
System, troubleshooting ........................................ 4-3-5
Emergency preparation ............................................. 1-2-6
Engine
Access door ........................................................... 3-2-2
Cold weather warm-up........................................... 2-2-4
Coolant temperature gauge .........................2-1-1, 2-1-2
Oil change.............................................................. 3-7-1
Oil filter, replace ..................................................... 3-7-1
Oil level check........................................................ 3-4-1
Speed control knob ................................................ 2-1-4
Starting................................................................... 2-2-2
Cold weather ...................................................... 2-2-3
Troubleshooting ..................................................... 4-3-2
Valve lash (clearance) adjustment ......................... 3-8-3
Engine coolant temperature
Indicator .......................................................2-1-1, 2-1-2
Engine oil
Pressure indicator ........................................2-1-1, 2-1-2
Sample................................................................... 3-6-3
Engine preheat
Operational checks ................................................ 4-2-3
Engine specifications................................................. 4-6-1
Explosion
Battery.................................................................... 1-2-5
F
Filter
Air cleaner.............................................................. 3-7-3
Final fuel, replace................................................... 3-7-2
Hydraulic tank replace .................................3-6-2, 3-7-3
Pilot system, replace.............................................. 3-8-2
Fire prevention........................................................... 1-2-4
Fluid
Change hydraulic tank ........................................... 3-9-2
Hydraulic level........................................................ 3-4-1
Fluid analysis test kit ................................................. 3-2-5
Front joint pins
Grease ................................................................... 3-5-2
Fuel
Diesel ...........................................................3-1-1, 3-1-3
Gauge ..........................................................2-1-1, 2-1-2
Handling and storing .............................................. 3-1-2
Level indicator..............................................2-1-1, 2-1-2
Lubricity.................................................................. 3-1-1
Tank ....................................................................... 3-2-4
Gauges
Location ................................................................. 2-1-1
Locationn of ........................................................... 2-1-2
Grease....................................................................... 3-1-9
Front joint pins ....................................................... 3-5-2
Swing bearing ........................................................ 3-6-1
H
Handhold use ............................................................ 1-3-1
Hardware torque values
Metric ................................................................... 4-1-13
Unified inch .......................................................... 4-1-12
Hazards
Avoiding ................................................................. 1-3-2
Heater and air conditioning
Operational checks ................................................ 4-2-8
High-pressure oils
Avoid ...................................................................... 1-2-3
Horn circuit
Operational checks ................................................ 4-2-6
Hose
Coolant.......................................................3-9-1, 3-10-1
Hour meter............................................ 2-1-1, 2-1-2, 3-2-1
Hydraulic
Breaker .................................................................. 3-2-5
Control shutoff lever............................................... 2-1-5
Crusher .................................................................. 3-2-5
Fluid change .......................................................... 3-9-2
Fluid tank level check............................................. 3-4-1
Oil specification...................................................... 3-1-8
Suction screen, clean............................................. 3-9-2
Sump drain............................................................. 3-6-2
System troubleshooting ......................................... 4-3-7
Tank filter replace.........................................3-6-2, 3-7-3
Hydraulic fluid tank pressurization
Operational checks .............................................. 4-2-10
Hydraulic system
Bleed procedure..................................................... 4-1-5
I
Indicator
Alternator output .................................................... 2-1-2
Alternator voltage................................................... 2-1-1
Auto idle ................................................................. 2-1-2
Engine coolant temperature.........................2-1-1, 2-1-2
Engine oil pressure ......................................2-1-1, 2-1-2
Fast travel mode .................................................... 2-1-2
Fuel level......................................................2-1-1, 2-1-2
Continued on next page
Index-2
080913
PN=2
Index
Page
Page
Hour meter ............................................................. 2-1-2
Location ................................................................. 2-1-1
Location of ............................................................. 2-1-2
Pre-heat .......................................................2-1-1, 2-1-2
System failure ........................................................ 2-1-2
Injection
Nozzle .................................................................... 4-1-1
Pump...................................................................... 4-1-1
Inspect machine ........................................................ 1-2-2
Interval chart
Service .........................................................3-2-6, 3-2-8
Towing.................................................................. 2-2-14
Machine inspection.................................................... 1-2-2
Machine modifications
Avoid ...................................................................... 1-2-2
Machine movement
Unintended............................................................. 1-3-1
Machine tip over
Avoiding ................................................................. 1-3-3
Maintenance
Access cover.......................................................... 3-2-2
Machine position .................................................... 3-2-1
Metal pins .................................................................. 1-4-2
Metric bolt and screw torque values ........................ 4-1-13
Monitor and gauges, engine off
Operational checks ................................................ 4-2-2
Monitor and gauges, engine on
Operational checks ................................................ 4-2-7
Monitor panel...................................................2-1-1, 2-1-2
Functions ............................................................... 2-1-1
Moving parts
Safety..................................................................... 1-2-3
Servicing ................................................................ 1-2-3
Multi-function
Control lever........................................................... 2-2-7
J
Jump starting ............................................................. 4-1-3
K
Knob
Engine speed control ............................................. 2-1-4
L
Lever
Cab door release ................................................... 2-1-7
Hydraulic control shutoff ........................................ 2-1-5
Left control ............................................................. 2-2-6
Location ................................................................. 2-1-4
Pilot control shutoff ................................................ 2-1-5
Right control........................................................... 2-2-6
Steering.................................................................. 2-2-5
Lift capacity
Cab, standard arm ................................................. 4-6-8
Canopy, standard arm............................................ 4-6-6
Lift Capacity
Cab, long arm ........................................................ 4-6-9
Canopy, long arm................................................... 4-6-7
Lifting ....................................................................... 2-2-14
Machine ............................................................... 2-2-15
Lifting objects
Special care ........................................................... 1-3-4
Light circuit
Operational checks ................................................ 4-2-4
Lubricants, Safety
Safety, Lubricants .................................................. 3-1-6
Lubricate
Blade pins .............................................................. 3-7-2
Bucket and link pins ............................................... 3-5-1
Swing gear ............................................................. 3-7-1
Lubricity of diesel fuel ................................................ 3-1-1
M
Machine
Clean regularly....................................................... 4-1-5
Lifting ................................................................... 2-2-15
Specifications......................................................... 4-6-2
O
Oil
Engine sample ....................................................... 3-6-3
Filter engine ........................................................... 3-7-1
Gear oil
Sample ............................................................... 3-7-3
Hydraulic sample ................................................... 3-7-3
Level engine........................................................... 3-4-1
Level travel gearbox............................................... 3-6-1
Specification hydraulic ........................................... 3-1-8
Specification track gearbox.................................... 3-1-8
Travel gearbox, change ......................................... 3-8-1
Oil cooler
Clean...................................................................... 3-3-1
Operation qualification............................................... 1-2-1
Operational checkout
Operator station, engine on ................................... 4-2-6
Operator station, key switch on, engine off............ 4-2-1
Operational checks
Blade function ...................................................... 4-2-15
Dig function drift ................................................... 4-2-12
Engine preheat....................................................... 4-2-3
Heater and air conditioning .................................... 4-2-8
Horn circuit............................................................. 4-2-6
Hydraulic fluid tank pressurization ....................... 4-2-10
Light circuit............................................................. 4-2-4
Monitor and gauges, engine off ............................. 4-2-2
Monitor and gauges, engine on ............................. 4-2-7
Pilot control shut-off switch .................................... 4-2-9
Pilot controller pattern, ISO excavator pattern ..... 4-2-11
Pilot controller pattern, SAE backhoe pattern ...... 4-2-10
Swing dynamic brake........................................... 4-2-12
Continued on next page
Index-3
080913
PN=3
Index
Page
Page
Travel alarm ........................................................... 4-2-9
Travel lever and pedal operation ........................... 4-2-3
Travel speed change ........................................... 4-2-15
Travel system tracking ......................................... 4-2-13
Travel system tracking while operating a
dig function......................................................... 4-2-14
Washer circuit, cab ................................................ 4-2-5
Wiper circuit, cab ................................................... 4-2-5
Operator Convenience .............................................. 1-1-1
Operator station
Tilting procedure .................................................... 3-2-3
Operator station, engine on
Operational checkout ............................................. 4-2-6
Operator station, key switch on, engine off
Operational checkout ............................................. 4-2-1
Operator's manual compartment ............................. 2-1-10
P
Panel
Switch .................................................................... 2-1-3
Parking machine...................................................... 2-2-13
Pattern conversion
Control levers......................................................... 2-2-7
Pedal
Auxiliary ................................................................. 2-2-8
Boom-swing ........................................................... 2-2-8
Location ................................................................. 2-1-4
Steering.................................................................. 2-2-5
Periodic maintenance chart ....................................... 3-2-1
Pilot
Control shutoff lever............................................... 2-1-5
System oil filter, replace ......................................... 3-8-2
Pilot control shut-off switch
Operational checks ................................................ 4-2-9
Pilot controller pattern, ISO excavator
pattern
Operational checks .............................................. 4-2-11
Pilot controller pattern, SAE backhoe pattern
Operational checks .............................................. 4-2-10
Pilot shutoff lever ....................................................... 1-3-1
Pre-heat
Indicator .......................................................2-1-1, 2-1-2
Pre-start inspection.................................................... 2-2-1
Product identification number .................................... 4-5-1
Protective equipment................................................. 1-2-2
Pump
Service ................................................................... 4-1-1
Q
Quick coupler
Bucket install.......................................................... 4-1-9
R
Radiator
Drain ..........................................................3-9-1, 3-10-1
Radiator core
Clean...................................................................... 3-3-1
Recovery tank
Coolant level .......................................................... 3-4-4
Riding machine.......................................................... 1-3-2
Rubber track
Check sag .............................................................. 3-4-4
Rubber track care .................................................... 4-1-10
S
Safety
Operator's seat ...................................................... 1-3-1
Safety equipment....................................................... 1-2-2
Safety features .......................................................... 1-1-1
Safety information
Recognizing ........................................................... 1-2-1
Safety instructions ..................................................... 1-2-1
Safety symbols .......................................................... 1-2-1
Safety, Avoid High-Pressure Fluids
Avoid High-Pressure Fluids ................................... 1-2-3
Seat
Adjustment ........................................................... 2-1-10
Seat belt .................................................................... 3-4-7
Use and maintenance ............................................ 1-3-1
Secondary exit
Tool ........................................................................ 2-1-9
Window .................................................................. 2-1-8
Service
interval chart ................................................3-2-6, 3-2-8
Servicing machine safely........................................... 1-4-1
Slopes
Driving up............................................................. 2-2-11
Specification
Cooling system ..........................................3-9-2, 3-10-2
Hydraulic oil ........................................................... 3-1-8
Travel gearbox oil .................................................. 3-1-8
Starter motor.............................................................. 3-8-3
Steel track
Check sag .............................................................. 3-4-6
Steering
Machine ................................................................. 2-2-5
Steps use................................................................... 1-3-1
Storage
Machine ................................................................. 4-4-1
Monthly .................................................................. 4-4-1
Storing fuel ................................................................ 3-1-2
Swing
Area cleaning ....................................................... 2-2-11
Bearing, grease...................................................... 3-6-1
Swing dynamic brake
Operational checks .............................................. 4-2-12
Continued on next page
Index-4
080913
PN=4
Index
Page
Page
Swing gear
Lubricate ................................................................ 3-7-1
Switch panel .............................................................. 2-1-3
Travel system tracking
Operational checks .............................................. 4-2-13
Travel system tracking while operating a dig
function
Operational checks .............................................. 4-2-14
Trip meter .................................................................. 2-1-6
Troubleshooting
Electrical system .................................................... 4-3-5
Engine.................................................................... 4-3-2
Hydraulic system.................................................... 4-3-7
T
Tank
Fuel ........................................................................ 3-2-4
Tip over
Avoiding ................................................................. 1-3-3
Tool
Secondary exit ....................................................... 2-1-9
Toolbox .................................................................... 2-1-10
Torque charts
Metric ................................................................... 4-1-13
Unified inch .......................................................... 4-1-12
Towing
Machine ............................................................... 2-2-14
Track
Conversion........................................................... 4-1-12
Sag adjustment ...................................................... 3-4-7
Sag check ....................................................3-4-4, 3-4-6
Sag, general information........................................ 3-4-6
Shoe cap screw hardware ................................... 4-1-10
Track care
Rubber ................................................................. 4-1-10
Track shoes
Select ................................................................... 2-2-11
Transport
Loading and unloading machine .......................... 2-2-13
Travel
Gearbox oil change................................................ 3-8-1
Gearbox oil level check.......................................... 3-6-1
Gearbox oil specification........................................ 3-1-8
Travel alarm
Operational checks ................................................ 4-2-9
Travel lever and pedal operation
Operational checks ................................................ 4-2-3
Travel speed change
Operational checks .............................................. 4-2-15
U
Unified inch bolt and screw torque values ............... 4-1-12
V
Valve
Control ................................................................... 4-1-1
W
Washer circuit, cab
Operational checks ................................................ 4-2-5
Washer fluid
Check..................................................................... 3-2-4
Waste disposal .......................................................... 1-2-5
Water separator
Drain ...................................................................... 3-4-3
Welding...................................................................... 4-1-4
Welding repairs.......................................................... 1-4-2
Window
Rear ....................................................................... 2-1-9
Secondary exit ....................................................... 2-1-8
Side........................................................................ 2-1-9
Wiper circuit, cab
Operational checks ................................................ 4-2-5
Work site hazards
Avoid ...................................................................... 1-3-2
Index-5
080913
PN=5
Index
Index-6
080913
PN=6